JP3792414B2

JP3792414B2 - Continuous manufacturing equipment for steel sleepers

Info

Publication number: JP3792414B2
Application number: JP29860698A
Authority: JP
Inventors: 政文矢野; 明史佐藤; 俊弘大徳屋; 孝雄山本; 雅登永島
Original assignee: Navitas Co Ltd; Nippon Steel Corp
Current assignee: Navitas Co Ltd; Nippon Steel Corp
Priority date: 1998-10-20
Filing date: 1998-10-20
Publication date: 2006-07-05
Anticipated expiration: 2018-10-20
Also published as: JP2000117376A

Description

【０００１】
【発明の属する技術分野】
本発明は、鉄道等に用いられる鋼製枕木の製造設備に係り、更に詳しくは枕木の孔加工と端曲げ加工を連続的に行う鋼製枕木の連続製造設備に関する。
【０００２】
【従来の技術】
近年、木材資源の枯渇による木製枕木の高価格化や、コンクリート製枕木の廃棄困難性等から鋼製枕木が使用されるようになり、種々の形態のものが開発され実用化されている。
図１５（Ａ）〜（Ｅ）に示す鋼製枕木２００、２０１は、所定長さに切断された鋼製の溝形部材２０２、２０２ａの溝底部２０３、２０４の所定位置に、レール取付け孔２０５、２０６、２０７を形成し、両端部２０８、２０８ａ、２０９、２１０に端曲げ加工を施している。レール取付け孔２０５、２０６、２０７の形状は、これらに取付けられる締結板の形状によって種々の形状があり、例えば、ボルト及びナットを使用するＡＰ型又はナブラ型（取付け孔２０５、２０６）や、ボルト及びナットを使用しない係止部材を使用するバンドロール型（取付け孔２０７）等がある。両端部２０８、２０８ａ、２０９、２１０の形状は、溝形部材２０２、２０２ａの溝底部２０３、２０４を上にしたとき、下方に折れ曲がると共に、幅方向に一定の幅まで拡幅することによって、道床ブラストに食い込み、横抵抗力が大きくなるように形成されている。
【０００３】
従来、鋼製枕木の製造を行うときには、まず、孔開け作業台に溝形部材を人力、リフトカー又はホイストによって１本ずつ載置して孔開け加工を行い、作業終了後は、再度人力、リフトカー又はホイストによって孔開け作業台から除去し、仮置き台に集積していた。
そして、孔開け作業終了後の溝形部材を、仮置き台から１本ずつ人力、リフトカー又はホイストでプレス装置に載置し、端曲げ加工を行った後、再度人力、リフトカー又はホイストによってプレス装置から除去していた。その後、バリ取り等の後処理、製品検査等の工程を経て出荷されていた。この製造工程を経ることによって、所定形状の製品を作ることができた。特に、小ロットの製品を多数作るときには、設備の変更も少なく費用の節約にもなった。
【０００４】
【発明が解決しようとする課題】
しかしながら近年、鋼製枕木の生産量の増加に伴い、鋼製枕木の形状は洗練され、一般的な形状として統一されてきたので、一度に大量の製品を生産することが必要となってきた。
前記従来の鋼製枕木の製造設備では、大量の製品を作る場合には生産効率が悪く、また、前記作業台や装置等へ部材をセットするときには、人力によって行っていたので、品質が安定しないという問題があった。
本発明はかかる事情に鑑みてなされたもので、孔開けと端曲げを連続的に行うことができると共に、品質を安定させることができる鋼製枕木の連続製造設備を提供することを目的とする。
【０００５】
【課題を解決するための手段】
前記目的に沿う請求項１記載の鋼製枕木の連続製造設備は、所定の長さに切断された溝形部材に、レール取付け孔を形成すると共に、プレス装置によって両側に端曲げ加工を行う鋼製枕木の製造設備であって、溝底部を下にして前記溝形部材を搬送し、前部に複数の該溝形部材を蓄える第１のコンベアと、前記第１のコンベアによって搬送された前記溝形部材を個々に取り出して仮置き載置する中間載置台と、前記中間載置台上に載った前記溝形部材を反転して孔加工作業台に載せ、又は該孔加工作業台に載置されて孔加工の終了した前記溝形部材を再度前記中間載置台に反転して載せる反転装置と、前記孔加工作業台に載った前記溝形部材を所定位置に位置合わせを行う第１の位置決め装置と、前記孔加工作業台上に位置決めされた前記溝形部材に、前記レール取付け孔の孔加工を行う孔加工手段と、前記孔加工が終了して、前記中間載置台に載った溝形部材をプレス加工位置の手前まで該溝形部材の長手方向に搬送する第２のコンベアと、進退可能となって、前記第２のコンベアによって前記プレス加工位置まで搬送された溝形部材を、前記プレス加工位置に載置する仮受け装置と、前記プレス加工位置に設けられ、両側に下金型を、中央に受け台を有する下型と、これらに対応して両側に上金型を、中央に押圧台を有する上型とを備えたプレス装置と、前記プレス装置に載った前記溝形部材を所定位置に位置合わせを行う第２の位置決め装置と、プレス加工が終了して、前記プレス装置に載った前記溝形部材を該プレス装置から取り出す搬出装置と、前記搬出装置によって、取り出された前記溝形部材を製品取り出し口に搬出する第３のコンベアとを有する。
【０００６】
そして請求項２記載の鋼製枕木の連続製造設備は、請求項１記載の鋼製枕木の連続製造設備において、前記孔加工手段は、多関節ロボットと、該多関節ロボットによって予め決定されたプログラムによって３次元的に制御されるプラズマトーチと、これに付設する機器とを有している。
請求項３記載の鋼製枕木の連続製造設備は、請求項１又は２記載の鋼製枕木の連続製造設備において、前記孔加工作業台は、前記溝形部材の溝底部を上にして、該溝底部の裏面を所定高さに保つ支持台を備えている。
請求項４記載の鋼製枕木の連続製造設備は、請求項３記載の鋼製枕木の連続製造設備において、前記第１の位置決め装置は、前記溝形部材が長手方向に自由に移動可能な前記支持台と、該支持台上に載っている前記溝形部材の長手方向の両外方向にそれぞれ対向して設けられた押圧部材と、それぞれの該押圧部材をロープを介して同期して引っ張り、前記溝形部材のセンタリングを行うエアシリンダーと、該エアシリンダーによるセンタリングの解除時に、前記押圧部材を前記溝形部材の長手方向の外側に付勢するカウンターウエイトとを有する。
【０００７】
請求項５記載の鋼製枕木の連続製造設備は、請求項１〜４のいずれか１項に記載の鋼製枕木の連続製造設備において、前記第１のコンベアは、該第１のコンベア上の移動方向の前部に前記溝形部材の幅に合わせて取付けられ、該第１のコンベア上を横移動する隣り合う２つの前記溝形部材の移動を個々に止める第１、第２のストッパーを有し、後方の前記第２のストッパーを作動させて前方の前記第１のストッパーを解除することによって、前記溝形部材を１本のみ該第１のコンベアによってそのまま搬送する。
請求項６記載の鋼製枕木の連続製造設備は、請求項１〜５のいずれか１項に記載の鋼製枕木の連続製造設備において、前記反転装置は、下部が前記中間載置台と重合した断面コ字状の金物内に配置された前記第１のコンベア又は前記溝形部材に後続するプッシャによって該金物内に搬送された前記溝形部材の横移動を止める少なくとも２つの縦ローラと、前記金物内に嵌入して前記縦ローラに当接した前記溝形部材を上から押圧保持するパッドと、該パッドによって保持された前記溝形部材を前記金物の基端部を中心にして該金物ごと１８０度回転する回転駆動源とを有する。
【０００８】
請求項７記載の鋼製枕木の連続製造設備は、請求項６記載の鋼製枕木の連続製造設備において、前記中間載置台は、前記溝形部材を幅方向に搬送する固定ローラと、該固定ローラより上位位置に突出可能となって、搭載された前記溝形部材を長手方向に移動させる昇降ローラとを有する。
請求項８記載の鋼製枕木の連続製造設備は、請求項１〜７のいずれか１項に記載の鋼製枕木の連続製造設備において、前記第２の位置決め装置は、前記溝形部材の幅方向のセンタリングを行う対となるガイド板を前記下型に有する。
請求項９記載の鋼製枕木の連続製造設備は、請求項１〜８のいずれか１項に記載の鋼製枕木の連続製造設備において、前記搬出装置は、前記両側の下金型と前記中央の受け台との間に先部の爪が侵入し、前記プレス加工の終了した溝形部材を下から持ち上げた後水平移動して取り出すリフト機構及び水平移動機構を有する。
【０００９】
【発明の実施の形態】
続いて、添付した図面を参照しつつ、本発明を具体化した実施の形態について説明し、本発明の理解に供する。
図１に示すように、本発明の一実施の形態に係る鋼製枕木の連続製造設備１０は、所定の長さに切断された溝形部材１１の溝底部１２を下にして溝形部材１１を搬送し、前部１３に複数の溝形部材１１を蓄える第１のコンベア１４と、第１のコンベア１４によって搬送された溝形部材１１を個々に取り出して孔加工に備えて仮置き載置する中間載置台１５を有している。リフトカー等で、第１のコンベア１４に溝形部材１１を複数載置すると、第１のコンベア１４は前方の作業状況をセンサー等で感知して溝形部材１１を連続的に送り出していく。
ここにいう所定の長さとは、鋼製枕木を製造するために必要な長さをいい、例えば２０００〜３０００ｍｍの長さをいう。
【００１０】
そして、鋼製枕木の連続製造設備１０は、中間載置台１５上に載った溝形部材１１を反転して孔加工作業台１６に載せ、又は孔加工作業台１６に載置されて孔加工の終了した溝形部材１１を再度中間載置台１５に反転して載せる反転装置１７と、孔加工作業台１６に載った溝形部材１１を所定位置に位置合わせする第１の位置決め装置１８と、孔加工作業台１６上に位置決めされた溝形部材１１に、レール取付け孔の孔加工を行う孔加工手段２０とを有して孔加工を行っている。孔加工作業台１６への載置、位置決め、孔加工を自動的に行うことによって、鋼製枕木の品質の均一化を図っている。
ここにいう所定位置とは、溝形部材の長手方向の中心位置をいう。
【００１１】
更に、鋼製枕木の連続製造設備１０は、孔加工の終了後は、反転装置１７によって再度反転され、中間載置台１５に載った溝形部材１１をプレス加工位置２２の手前まで溝形部材１１の長手方向に搬送する第２のコンベア２１と、進退可能となって、第２のコンベア２１によってプレス加工位置２２の手前まで搬送された溝形部材１１を、プレス加工位置２２に載置する仮受け装置２３と、プレス加工位置２２に設けられ、両側に下金型２４、２５を、中央に受け台２６を有する下型２７と、図１１に示すように、これらに対応して両側に上金型２８、２９を、中央に押圧台３０を有する上型３１とを有するプレス装置３２と、プレス装置３２に載った溝形部材１１を所定位置に位置合わせする図示しない第２の位置決め装置によってプレス加工を行う。プレス位置への搬送、位置調整も自動で行っている。
ここにいう所定位置とは、溝形部材の長手方向の中心位置をいう。
プレス加工終了後、鋼製枕木の連続製造設備１０では、プレス装置３２に載った溝形部材１１をプレス装置３２から取り出す搬出装置３４と、搬出装置３４によって、取り出された溝形部材１１を製品取り出し口３５に搬出する第３のコンベア３６とによって製品を搬出することによって連続製造を行っている。以下、これらについて詳しく説明する。
【００１２】
図１、図２に示すように、第１のコンベア１４は、例えば、チェーンコンベアを使用している。チェーンには、プレート３７、３８を介してローラ３９が取付けられ、溝形部材１１の移動を容易にしている。
なお、溝形部材１１は溝底部１２を下にして搬送されるが、溝底部１２を上にして搬送することもできる。この場合は、チェーンコンベアの隣り合うプレート３７の間に溝形部材１１の側端部４０が嵌入して外れなくなることがあるので、プレート３７、３８とローラ３９を外し、代わりにスラット等を取付けて使用するとよい。また、第１のコンベア１４上には、複数の溝形部材１１を蓄えておくことができ、本実施の形態では、１３本程度まで蓄えておくことが可能である。蓄える本数を増やしたいときは、第１のコンベア１４の移動方向の長さを長くすればよい。
【００１３】
図１、図２（Ａ）に示すように、第１のコンベア１４上の移動方向の前部１３には、溝形部材１１の幅に合わせて取付けられ、第１のコンベア１４上を横移動する隣り合う２つの溝形部材１１の移動を個々に止める第１、第２のストッパー４１、４２が設けられている。図２（Ｂ）に示すように、第１のストッパー４１は、第１のコンベア１４の進行方向に直交する方向に回動可能に取付けられたストッパー片４３、４４を、アーム４５を介してエアシリンダー４６で同時に回動させるリンク機構を構成している。第１のコンベア１４は、鋼製枕木の連続製造設備１０の稼働中は、常時作動していて、溝形部材１１の移動・停止は、前記第１、第２のストッパー４１、４２によって管理する。
エアシリンダー４６を作動させると、ピストンロッド４７が突出して、それぞれのストッパー片４３、４４が回動し、第１のコンベア１４の上面よりも上側に突出することによって、溝形部材１１を止めることができる。また、作動を解除したときには、ピストンロッド４７が元の位置に戻り、ストッパー片４３、４４は第１のコンベア１４の上面より下側である図中の二点鎖線の位置まで回動し、溝形部材１１は第１のコンベア１４の流れ方向前方に移動する。なお、第２のストッパー４２の側面図は図示しないが、第１のストッパー４１と同一の形状となっている。
【００１４】
第１、第２のストッパー４１、４２の中間位置には図示しない検出器が設けられ、これによって溝形部材１１の位置を確認し、第１、第２のストッパー４１、４２の動きを制御することができる。
【００１５】
第１、第２のストッパー４１、４２の運転は次のように行われる。
第１のコンベア１４上に設けられた検出器（以下、検出器ａという）と第２のストッパー４２は連動し、前方の中間載置台１５に設けてある検出器（以下、検出器ｂという）と第１のストッパー４１も連動する。
鋼製枕木の連続製造設備１０が作動中であるとき、第１のコンベア１４上の複数の溝形部材１１は、順に前方に送り出される。検出器ａが溝形部材１１を検知した時（検知信号を送っている時（以下すべて同様））は、第２のストッパー４２によって検出器ａによって検出された溝形部材１１より後ろ側の溝形部材１１は止められる。検出器ａが先行する溝形部材１１を検知していないとき、第２のストッパー４２は解除され、溝形部材１１は前方に移動する。中間載置台１５上に溝形部材１１があることを、検出器ｂが検知した場合は、第１のストッパー４１によって検出器ｂによって検出された溝形部材１１より後ろ側の溝形部材１１は止められる。このとき、検出器ａも先行する溝形部材１１として検知するので第２のストッパー４２も作動し、後続の溝形部材１１は、第２のストッパー４２によって止められた状態になっている。
中間載置台１５上の作業が終了して、検出器ｂが中間載置台１５上の溝形部材１１を検知しなくなると、第１のストッパー４１が解除されて、溝形部材１１を１本のみ第１のコンベア１４によって前部１３に搬送することができる。
【００１６】
第１のストッパー４１の解除により溝形部材１１は、図３に示すように第１のコンベア１４の前端部４８まで運ばれ、第１のコンベア１４の上面と同じ高さで、前端部４８から中間載置台１５上まで渡設されている固定ローラの一例であるホイールコンベア４９上に乗り上げた状態で止まっている。ホイールコンベア４９の列数は任意であるが本実施の形態では、２列としている。これによって、溝形部材１１の表面に傷をつけることなく搬送することができる。
【００１７】
第１のコンベア１４を側面視したときに、第２のストッパー４１と重合する位置には、プッシャの一例である押し出し部材５０が設けてある。押し出し部材５０は、第１のコンベア１４の側方から見たときの形状が略Ｌ形の金属製の部材で、その中央付近の折り曲げ部分が、第１のコンベア１４の内部にあって溝形部材１１の長手方向に設けた回転軸５１に、回動可能に２以上取付けられている。そして折り曲げ部分から上側には、第１のコンベア１４の上方に突出可能な上側部５４が設けられ、折り曲げ部分から右側には、その先端に復帰錘５３を有している右側部５２が設けられている。
溝形部材１１が押し出し部材５０の上側を移動するときには、押し出し部材５０は、上側部５４を右方向から押されて略１５度反時計方向に回動し、図中の二点鎖線の位置まで回動するので、溝形部材１１は回動した押し出し部材５０の上側を通過し、移動を妨げられることはない。また、復帰錘５３の自重によって、押し出し部材５０は、溝形部材１１の通過後に時計方向に回動し、図中の実線の位置まで自動的に戻ることができる。
【００１８】
押し出し部材５０は、エアシリンダー５５に接続され、第１のコンベア１４の移動方向と同一方向に移動可能となっている。溝形部材１１が押し出し部材５０の上側を通過した後、ホイールコンベア４９に一部乗り上げた状態になると、押し出し部材５０は、エアシリンダー５５によって中間載置台１５の方向に向かって押し出される。元の状態に戻っている押し出し部材５０は、第１のコンベア１４の上方に突出している上側部５４によって溝形部材１１全体が中間載置台１５の上に位置するまで押して移動させる。図３〜図５に示すように、中間載置台１５の上には、反転装置１７の一部であって、断面コ字状の金属製（金物）であり、その下部が中間載置台１５と重合し、一定間隔をおいて溝形部材１１を保持する複数の保持部材５８がその開口部６３を開口して待機しており、その内部に配置されている２以上の縦ローラ５６によって、溝形部材１１の横移動は止められる。押し出し部材５０は溝形部材１１が反転装置１７の中に入った後、エアシリンダー５５によって元の位置に戻される。
【００１９】
反転装置１７は、中間載置台１５と、中間載置台１５と平行に設けられた孔加工作業台１６の中間（保持部材５８の基端部）に保持部材５８ごと１８０度反転可能な反転軸５７を有し、反転軸５７には、反転軸５７の軸方向に複数の保持部材５８が、その基端部を中心に反転するように取付けられている。保持部材５８の数は２以上で任意であるが本実施の形態では３としている。２以上必要とするのは、反転時の保持部材５８のねじれによる溝形部材１１の変形を抑えるためである。反転軸５７の両端部は、軸受５９で支持されている。また、反転軸５７の一側の軸受５９の外側には、反転軸５７と軸心を同一にする回転駆動源の一例である駆動モータ６０が軸継手を介して接続されている。
また、保持部材５８内に嵌入して縦ローラ５６に当接した溝形部材１１を上から押圧保持するパッド６１を有し、パッド６１によって保持された溝形部材１１を駆動モータ６０によって、反転軸５７を中心にして保持部材５８ごと１８０度回転する。保持部材５８の上部には、パッド６１の上下動を行うシリンダー６２が設けてある。なお、パッド６１は、溝形部材１１に傷をつけないように柔らかい材質のものを使用する方が望ましい。本実施の形態では、ウレタン製の物を使用している。
【００２０】
保持部材５８の開口部６３側の上部には、保持部材５８の反転軸５７の軸方向と平行に短軸６６が対となる軸受６６ａを介して取付けられている。短軸６６には、ブラケット６７とこれと約１５０度の角度をなして一体化した固定軸６５の基部が回動可能に取付けられている。固定軸６５には補助ローラ６４が回転自在に取付けられ、ブラケット６７の先部にはピストンロッド６８の先部に取付けられている取付け金具６８ａが取付けられ、シリンダー６９を伸縮することによって、ブラケット６７が短軸６６を介して約６０度回動し、補助ローラ６４が保持部材５８の開口部６３側で開閉するようになっている。
補助ローラ６４で開口部６３を閉じることによって、保持部材５８を反転させるときに溝形部材１１の飛び出しを防ぐことができる。また、閉じた状態のときの補助ローラ６４の固定軸６５は縦ローラ５６の回転軸と平行になるので、孔加工の終了後に、溝形部材１１を長手方向に搬送するときには、幅方向の位置ずれを防止することができる。
【００２１】
図３に示すように、第１のコンベア１４から押し出し部材５０によって押し出された溝形部材１１は、ホイールコンベア４９上を通って、縦ローラ５６に当接するまで移動する。このとき、図５に示すようにシリンダー６９はロッドが収縮した状態で、補助ローラ６４は図中の二点鎖線で示す位置にあって、保持部材５８は開口した形状となっている。その後、シリンダー６２、６９を作動させ、パッド６１で溝形部材１１を上から押さえると共に、補助ローラ６４で、保持部材５８の開口部６３を閉じた状態（図中の実線部分）にする。
保持部材５８の底内側部７０は、ホイールコンベア４９の上側部７１よりも低い位置にある。このため、パッド６１が溝形部材１１の側端部４０を押さえているとき、溝形部材１１の溝底部１２は、保持部材５８の底内側部７０ではなくホイールコンベア４９の上側部７１を押圧している。この位置関係を保持したまま反転させると、ホイールコンベア４９は反転しないので、溝形部材１１の溝底部１２と保持部材５８の底内側部７０の間の距離だけ隙間が生じることになる。しかし、保持部材５８の反転が行われる間、シリンダー６２からの押圧力はパッド６１を介して常に溝形部材１１に伝えられているので、パッド６１が隙間の分だけ下がり、溝形部材１１を押圧するので反転中に隙間が生じることはない。
パッド６１によって溝形部材１１を押さえながら反転させることによって、溝形部材１１のがたつきによって傷が入るのを防ぐことができる。
【００２２】
溝形部材１１は、反転した後は孔加工作業台１６の上に載置される。図４に示すように、孔加工作業台１６上には、反転装置１７の保持部材５８の位置を避けて、溝形部材１１の裏面を所定高さに保つ支持台の一例である受けローラ７２が、セットされる溝形部材１１の長手方向に２カ所以上回転可能に設けられている。受けローラ７２は、溝形部材１１の幅方向に、軸受７３によって両端部を保持された受けローラ軸７４に１００ｍｍ程度の間隔を開けて、直径３００ｍｍ程度のものを２枚以上回転可能に取付けている。また、受けローラ７２は、厚さ１００ｍｍ程度のものを一枚使用することもでき、逆に枚数を３枚以上にすることもできる。溝形部材１１は、受けローラ７２によって、その長手方向に摺動することなく移動できるので、長手方向の位置決めが容易にでき、傷もつかない。
ここにいう所定高さとは、孔加工手段を行う工具と溝形部材の間に必要な隙間を確保するための高さをいう。
【００２３】
図６、図７に示すように、幅方向調整装置７５は、孔加工作業台１６の第１のコンベア１４から見て前側の基部に、孔加工作業台１６に載置される溝形部材１１の長手方向と平行に設けられた回転可能な支持軸７６と、支持軸７６の両側の端部を支持する軸受７７と、支持軸７６の両側に、軸受７７の取付け位置を避けて支持軸７６の半径方向外側であって略上方に向けて設けられ、支持軸７６と一体となって回動可能な腕部材７８、７９とを有している。腕部材７８、７９の先部には、孔加工作業台１６の方向に向けてブラケット８０がそれぞれ設けられ、ブラケット８０には、腕部材７８、７９に平行な軸８１と、軸８１に回転可能に取付けられた押圧ローラ８２とがそれぞれ取付けてある。腕部材７９の後ろ側であって、腕部材７９の上端より低い位置で、支持軸７６の中央付近をよけた部分にはシリンダー８３が取付けられている。
【００２４】
反転装置１７によって、孔加工作業台１６に溝形部材１１が載置されると、シリンダー６２によるパッド６１を介しての溝形部材１１への押圧が解除される。このときは、シリンダー８３はロッドが収縮した状態である。また、腕部材７８、７９は支持軸７６に垂直な位置から１５度程度シリンダー８３側に傾いた状態で支持されていて、押圧ローラ８２と溝形部材１１との間には隙間を有している。
孔加工作業台１６に溝形部材１１が載置され、シリンダー８３のロッドが伸びると、支持軸７６と一体になった腕部材７８、７９が略垂直になる位置まで回動する。このとき、押圧ローラ８２によって溝形部材１１はシリンダー８３側から押圧力を受け、反転装置１７の内部に取付けられた縦ローラ５６に当接するまで移動する。これによって、溝形部材１１の幅方向の位置を決めることができる。
【００２５】
シリンダー８３が支持軸７６の中央付近をよけた位置に取付けられているのは、孔加工を行うロボットの取付け位置と干渉しないためであるので、干渉しない位置であれば任意の位置に取付けてよい。
また、シリンダー８３の高さ方向の取付け位置も腕部材７８、７９の上端より低い位置にしてあるが、これはロボットのアームの動きを妨げないためである。ロボットの動きの妨げにならない範囲であれば、シリンダー８３の取付け高さを溝形部材１１の高さと略同一にして、支持軸７６と腕部材７８、７９による回動機構を省略して直線的に溝形部材１１を押圧することもできる。
【００２６】
図８に示すように、第１の位置決め装置１８は、孔加工作業台１６に載置される溝形部材１１が長手方向に自由に移動可能な受けローラ７２と、受けローラ７２上に載っている溝形部材１１の長手方向の両外方向にそれぞれ対向して設けられた押圧部材８４、８５と、それぞれの押圧部材８４、８５をロープ８６、８７を介して同期して内側に引っ張り、溝形部材１１のセンタリングを行うエアシリンダー８８と、エアシリンダー８８によるセンタリングの解除時に、押圧部材８４、８５を溝形部材１１の長手方向の外側に付勢するカウンターウエイト８９、９０とを有している。
エアシリンダー８８のピストンロッド９１は通常の状態（センタリングの解除時）では突出している。ピストンロッド９１にはブラケット９２が取付けられ、ブラケット９２には、例えば鋼製のロープ８６、８７が取付けられている。ロープ８６、８７は、プーリ９３、９４、９５によって向きを変えられ、押圧部材８４、８５の内側に取付けられている。押圧部材８４、８５の端面９６、９７間の距離は中心位置Ｓから左右均等になるように長さの調整がされている。また、押圧部材８４、８５、ブラケット９２は、溝形部材１１の長手方向に摺動可能な台８４ａ、８５ａ、９２ａにそれぞれ取付けられている。
【００２７】
第１の位置決め装置１８は、幅方向の位置決めを行う幅方向調整装置７５と同じタイミングで作動する。エアシリンダー８８が作動すると、ロープ８６、８７を介して押圧部材８４、８５に伝達される引張力によって押圧部材８４、８５は、同期して内側に移動する。溝形部材１１の長手方向の一側が押圧部材８４又は８５に当接し、そのまま押圧部材８４又は８５と一緒に内側に移動する。そして、溝形部材１１の長手方向の他側が、他側の押圧部材８５又は８４に当接した状態になると、溝形部材１１の移動は止まる。このとき、溝形部材１１の長手方向の中心位置Ｓから両端までの長さは等しくなっている。溝形部材１１の長さに誤差がある場合でも、その中心を基準に位置を合わせることができる。
なお、長さの違う枕木を製造する場合でも、押圧部材８４、８５は摺動可能な台８４ａ、８５ａ、９２ａにそれぞれ取付けられているので、調整が簡便にできる。
【００２８】
作業終了後、エアシリンダー８８の作動を解除すると、ロープ８６、８７が緩み、押圧部材８４、８５のそれぞれの内側への引張力も解除される。そして、押圧部材８４、８５の外側に取付けた解除ロープ９８、９９を介して取付けられたカウンターウエイト８９、９０によって、押圧部材８４、８５は外側に付勢力を加えられて移動するので、溝形部材１１の長手方向の両端部への固定が解除される。
本実施の形態では、溝形部材１１の固定には、エアシリンダー８８を使用しているが、例えば、それぞれ逆方向にねじ溝を切ったスクリューを介して、モータから両側の押圧部材８４、８５に駆動力を伝えても、同様に中心位置を合わせることができる。この場合、モータを逆方向に回せば解除もできるので、カウンターウエイト８９、９０を省略することができる。
【００２９】
図１に示すように、孔加工手段２０は、多関節ロボットと、多関節ロボットによって予め決定されたプログラムによって３次元的に制御されるプラズマトーチと、これに付設する機器によって行う。前記手順によって位置決め固定された溝形部材１１は、溝底部１２を上側にし、溝底部１２の裏面を、受けローラ７２によって高さ方向の基準にして固定されている。高さ方向の位置ずれは、溝形部材１１の厚みの寸法公差の範囲内となるので、精度よく加工できる。
孔加工の位置、形状としては、例えば、図１５（Ａ）、（Ｃ）の従来例に示すレール取付け孔２０５〜２０７を予めプログラムしておくことによって、自動的に孔加工を行うことができる。プラズマトーチによって加工された溝形部材１１の溝底部１２の裏面にはドロスが発生するが、例えばプレスによって孔加工を行った場合に発生する返りに比べ少量なので、簡単に落とすことができる。動作前・後の多関節ロボットのアームの位置は、孔加工作業台１６と重合しないようになっていて、反転装置１７が誤作動したときに溝形部材１１が多関節ロボットのアームとぶつかって破損することを防いでいる。
【００３０】
孔加工終了後は、反転装置１７のシリンダー６２が作動し、パッド６１によって溝形部材１１を押圧する。そして、再度反転して溝形部材１１は中間載置台１５上に載置され、シリンダー６２による押圧を解除される。
図９、図１０（Ａ）、（Ｂ）に示すように中間載置台１５の上部には、孔加工前と同様に幅方向に移動可能なホイールコンベア４９があり、孔加工終了後の溝形部材１１は、ホイールコンベア４９の上に載置される。
中間載置台１５は、溝形部材１１を幅方向に搬送するホイールコンベア４９と、ホイールコンベア４９より上位位置に突出可能となって、搭載された溝形部材１１を長手方向に移動させる昇降ローラ１００とを有している。昇降ローラ１００と、昇降ローラ１００が上部に連設された昇降台１０１と、昇降台１０１の長手方向の一側の下部に設けられた昇降ローラ１００を駆動する移動モータ１０２は、一体となって昇降できるように設けられている。
【００３１】
そして、昇降台１０１の他側の下部には昇降シリンダ１０３と、これに連動して作動するロッド１０４が昇降台１０１と長手方向を同じにして基台１０１ａに取付けられている。昇降台１０１の下方には、昇降シリンダ１０３に取付けられたロッド１０４の動作する方向と直交する水平軸１０６が軸受を介して基台１０１ａに複数設けられ、ロッド１０４と水平軸１０６は、回動ブラケット１０５によって連結され、水平軸１０６は、ロッド１０４の動きに応じて回動可能に取付けられている。水平軸１０６の両端部には水平軸１０６と一体となって回動可能な回動腕１０７がそれぞれ取付けられ、腕の先部に取付けられた支持軸１０８には、支持ローラ１０９が取付けられている。それぞれの支持軸１０８に取付けられた支持ローラ１０９によって昇降台１０１は支持され、高さを決められている。
【００３２】
孔加工が終了し、反転装置１７によって、中間載置台１５に溝形部材１１が載置されると、昇降シリンダ１０３が作動して、突出していたロッド１０４が昇降シリンダ１０３の方向へ引き込まれる。ロッド１０４によって回動ブラケット１０５の先部が力を受け、水平軸１０６が回動する。水平軸１０６と軸心の高さが同じ位置にあり、水平軸１０６を中心として水平軸１０６の上側方向に回動する支持ローラ１０９によって、昇降台１０１が持ち上げられ、昇降台１０１上に取付けられた昇降ローラ１００の高さの方がホイールコンベア４９の高さより高くなり、溝形部材１１は、昇降ローラ１００によって支持される。昇降台１０１の他側の側部は、保持腕１１０とその両側に設けられた回動軸を介して保持台１１１と接続されている。これによって、昇降台１０１の横方向への過度の移動を制限している。
【００３３】
昇降ローラ１００は移動モータ１０２によって駆動され、それぞれの昇降ローラ１００間に昇降台１０１と略同一の高さに取付けられたスプロケット１１２を介し、図１０（Ａ）に示す駆動チェーン１００ａ〜１００ｉによって連結されている。昇降ローラ１００、移動モータ１０２、スプロケット１１２は一体となって昇降するので、駆動チェーン１００ａ〜１００ｉが緩むことはない。また、昇降ローラ１００は、昇降ローラ１００より低い位置に設けられたスプロケット１１２と駆動チェーン１００ａ〜１００ｉによって駆動されるので、昇降時にホイールコンベア４９と干渉することはない。
昇降ローラ１００によって支持された溝形部材１１は、図５中の二点鎖線に示すように、ホイールコンベア４９によって支持されていたときよりも高い位置で支持されるが、反転装置１７の保持部材５８の高さ方向の隙間は十分確保されているので、保持部材５８と溝形部材１１が昇降時に衝突して互いに傷つくことはない。
昇降ローラ１００上に支持された溝形部材１１は、次工程のプレス装置３２（図１１、図１２参照）上に先行する溝形部材１１がないことをセンサー等で確認した後、移動モータ１０２から昇降ローラ１００に伝達される駆動力によって、移動することができる。
【００３４】
図１に示す第２のコンベア２１は、中間載置台１５の移動モータ１０２と同期して駆動され、中間載置台１５からプレス加工位置２２まで前進した仮受け装置２３まで溝形部材１１を運搬する。溝形部材１１の移動方向の左右に、溝形部材１１が通過する隙間をあけて、図示しないガイドローラを設けているので、運搬時の横方向の位置ずれを防止することができる。
【００３５】
図１、図１１、図１２（Ａ）に示すように仮受け装置２３は、プレス装置３２の作動時には後方に待避するようになっている。
仮受け装置２３は、溝形部材１１の幅方向に移動可能な方向にレール付きの固定台１１３を有し、その上部にエアシリンダー１１４によって前進可能な移動台１１５を有している。そして、移動台１１５にはシリンダー１１６によって上下移動が可能な仮受け台１１７が取付けられている。そして、仮受け台１１７の下部には、複数の仮受けローラ１１８が設けてあり、通常は第２のコンベア２１と高さ位置Ｈ１を同じにしている。
第２のコンベア２１から搬送されて来る溝形部材１１の高さ位置Ｈ１は、下金型２４、２５の高さ位置Ｈ２より高いので、下金型２４、２５との当たりを避けてプレス装置３２のプレス加工位置付近まで搬送することができる。プレス加工位置付近まで搬送された後は、溝形部材１１はシリンダー１１６により、下金型２４、２５の高さ位置Ｈ２より低い高さ位置Ｈ３まで下がり、下金型２４、２５に載置される。
【００３６】
溝形部材１１の搬送時には隙間をあけて設けているテーパローラ１２５、ガイドローラ１２６によって、横方向の位置ずれを防止することができる。
図１２（Ｂ）に示すように、テーパローラ１２５の円周部には、溝形部材１１の角部１１ａと角度を合わせたテーパが形成されている。溝形部材１１を所定位置まで搬送した後、図１１に示すように高さＨ３の位置まで下がったときは、テーパローラ１２５の上端部１２５ａの位置も溝形部材１１の溝部１２の下面より下がるので、エアシリンダー１１４を作動させ、移動台１１５をプレス装置３２の後方（図１２（Ａ）に示す位置）まで下げるときには、溝形部材１１に当たることはない。
【００３７】
溝形部材１１は、図１３（Ａ）、（Ｂ）に示す第２の位置決め装置１１９によって長手方向の位置を決められる。第２の位置決め装置１１９は、プレス装置３２の後部の両側で、プレス装置３２の上下動と、仮受け装置２３の前後動を邪魔しない位置に設けられている。第２の位置決め装置１１９は、プレス装置３２の下金型２４、２５上に載置される溝形部材１１の長手方向の両外方向にそれぞれ対向して設けられた溝側部押圧機構１２０、１２１と、それぞれの溝側部押圧機構１２０、１２１をロープ１２０ａ、１２１ａを介して同期して引っ張り、溝形部材１１のセンタリングを行うエアシリンダー１２２と、エアシリンダー１２２によるセンタリングの解除時に、溝側部押圧機構１２０、１２１をそれぞれプレス装置３２の後方に付勢するカウンターウエイト１２３、１２４とを有している。
【００３８】
溝側部押圧機構１２０、１２１は、複数の部品によるリンク機構を構成している。エアシリンダー１２２が作動すると、取付けられたロープ１２０ａ、１２１ａによって左右の溝側部押圧機構１２０、１２１の先部に取付けられた爪部１２７、１２８が同期して溝形部材１１を押圧する。このとき、爪部１２７、１２８は、図１３（Ｂ）に示すように、溝形部材１１の幅方向一側の側部のみ押圧する。また、溝形部材１１が載置されている下金型２４、２５は回転可能であり、位置決め時に摺動しないので、溝形部材１１に傷をつけることはない。
長手方向の位置決め後は、エアシリンダー１２２によって、センタリングを解除する。溝側部押圧機構１２０、１２１はリンク機構であり、爪部１２７、１２８が押圧していた溝形部材１１の両端部付近の垂直軸を中心に回動して、溝形部材１１の側方（プレス装置３２の後方）に移動するので、その後のプレス加工、また、後続する溝形部材１１の搬送を邪魔することはない。
【００３９】
爪部１２７、１２８は、取付け位置を変えることができ、例えば爪部１３０、１３１の位置に変更することによって、長さの違う鋼製枕木の製造にも対応できる。
プレス装置３２の上型３１を下げると、上金型２８、２９は、溝形部材１１の長手方向の両側の上部を押圧する。溝形部材１１の両側の下部は下金型２４、２５で支持されているので、その内側を上から押さえることになる。そのまま上金型２８、２９で押圧して、溝形部材１１の中央部が受け台２６に当接するまで両端部を曲げる。このとき、第２の位置決め装置１１９は下型２７に、受け台２６の、溝形部材１１の幅方向両側に、溝形部材１１の幅方向のセンタリングを行う図示しないガイド板を備えている。両ガイド板間は溝形部材１１の幅と略同一の幅に形成されていて、両ガイド板、中央の押圧台３０及び受け台２６によって、端曲げ加工のときの幅方向の位置ずれを防止することができる。
端曲げ加工終了後は、上型３１は元の位置まで上がり、プレス加工は終了する。
【００４０】
図１４（Ａ）、（Ｂ）に示す搬出装置３４は、プレス装置３２の下金型２４、２５と受け台２６との間に先部の爪１３３、１３４が侵入し、プレス加工の終了した溝形部材１１を下から持ち上げた後、水平移動して取り出すリフト機構１３５及び水平移動機構１３６を有している。リフト機構１３５は第３のコンベア３６の下部のプレス装置３２側に設けられ、爪１３３、１３４と、これが取付けられた水平腕部１３８とを有し、連結部材１３９を介してこれらと一体に上方向に動作可能なエアシリンダー１３７に取付けられている。水平移動機構１３６は、リフト機構１３５のエアシリンダー１３７に取付けられた固定部材１４０と、これと連結された水平連結腕１４１と、これを第３のコンベア３６の移動方向に平行移動させることが可能な第３のコンベア３６の出口側に設けてある図１に示す駆動手段１４３（例えばモータとギアボックスを有する）とを有し、固定部材１４０の下部に、第３のコンベア３６の移動方向と平行に設けられた移動手段の一例であるチェーンコンベア１４２上に載置されている。
【００４１】
プレス加工が終了した後、駆動手段１４３によって、水平連結腕１４１がプレス装置３２方向に突出する。これによって連結部材１３９は、図１４（Ｂ）に二点鎖線で示す位置から実線で示す位置までチェーンコンベア１４２上を移動する。そして、リフト機構１３５全体がプレス装置３２方向に移動し、先部にある爪１３３、１３４はプレス装置３２上にあるプレス加工後の溝形部材１１の下方に入る。次にエアシリンダー１３７を作動させると、リフト機構１３５の連結部材１３９、水平腕部１３８、爪１３３、１３４はそれぞれ上部に移動し、これによって、溝形部材１１の底部（爪部１３３、１３４で支える位置）は、プレス装置３２上であって、図中の二点鎖線の位置まで持ち上げられる。そして、この状態で駆動手段１４３によって水平連結腕１４１を元の位置まで戻し、溝形部材１１を図中の二点鎖線に示す第３のコンベア３６上に移動させる。この状態で、エアシリンダー１３７を突出させると、爪部１３３、１３４によって支持されていた溝形部材１１は、第３のコンベア３６上に載置される。第３のコンベア３６は、鋼製枕木の連続製造設備１０の運転時には常時作動しているので、この上に載置された溝形部材１１は製品取り出し口３５まで搬送される。製品取り出し口３５には、図示しない落下ガイドが取付けられていて、溝形部材１１の落下を防いでいる。
【００４２】
次に、溝形部材１１の加工をそれぞれの工程に沿って説明する。ここで、溝形部材１１は、先頭から順に溝形部材１１ａ、溝形部材１１ｂ、溝形部材１１ｃ・・とする。
第１のコンベア１４までは、リフトカーやホイスト、又は人力によって溝形部材１１を載置することができる。溝形部材１１ａ、１１ｂ、１１ｃ・・の順に第１のコンベア１４上に溝底部１２を下にして載置すると、図１に示す第１のコンベア１４上を前方に向けて移動する。第１のコンベア１４の搬送速度は任意であるが、本実施の形態では１０ｍ／ｍｉｎ程度としている。第１、第２のストッパー４１、４２は、第１、第２のストッパー４１、４２の間に設けられた検出器ａと中間載置台１５上に設けられた検出器ｂが溝形部材を検知していないので、溝形部材１１ａは第２のストッパー４２の位置で停止しないで通過する。
【００４３】
溝形部材１１ａが検出器ａを通過すると、第２のストッパー４２が溝形部材１１ａを検知し、溝形部材１１ｂ以降を停止させる。
溝形部材１１ａは第１のストッパー４１位置も通過して、中間載置台１５上に移動する。そして、検出器ｂによって第１のストッパー４１が溝形部材１１ａを検知する。
溝形部材１１ａが第１のストッパー４１位置から移動したので、検出器ａが検知しなくなり、第２のストッパー４２が解除される。そして、溝形部材１１ｂが第１のストッパー４１の位置まで移動し、検出器ａに検知され、第２のストッパー４２が作動して、溝形部材１１ｃ以降を停止させる。
反転装置１７によって溝形部材１１ａが反転され孔加工作業台１６に載置される。そして、孔加工手段２０によって孔加工され、再度反転装置１７によって中間載置台１５上に戻される。孔加工に要する時間は、使用するプラズマトーチや多関節ロボットの仕様によって変わるが、本実施の形態では、８０〜１６０秒程度である。また、このとき位置決めにかかる時間は１０秒程度である。
【００４４】
中間載置台１５が昇降シリンダ１０３によって上方に移動し、仮受け装置２３上に設置していた例えば検出装置（検出器ｃとする）によって、先行する溝形部材がないことを確認し、溝形部材１１ａを第２のコンベア２１上を通過させ、仮受け装置２３に移動させる。中間載置台１５が再度昇降シリンダ１０３によって下方に移動すると検出器ｂは溝形部材１１ａを検知しなくなり（検知信号を送らなくなり）、第１のストッパー４１が解除される。
すると溝形部材１１ｂは、中間載置台１５に運ばれ、溝形部材１１ａと同様に孔加工がおこなわれる。溝形部材１１ｃは、溝形部材１１ｂの孔加工が終了するまで、第１のストッパー４１によって停止している。
【００４５】
仮受け装置２３に載置された溝形部材１１ａは、長手方向の位置決めを行った後、プレス装置３２に載置される。仮受け装置２３がプレス装置３２の後方（図１の左方）に待避した後、溝形部材１１ａの両側の端曲げ加工、すなわちプレス加工が行われる。プレス加工に必要な時間は、位置決めに１０秒程度で端曲げ加工に５０秒程度である。
プレス加工終了後、搬出装置３４によって溝形部材１１ａは第３のコンベア３６上に載置され、製品取り出し口３５まで運ばれる。第３のコンベア３６の速さも第１のコンベア１４と同じく任意であるが、本実施の形態では１０ｍ／ｍｉｎ程度である。
そして、仮受け装置２３がプレス装置３２と重合する位置に戻り、仮受け装置２３上の検出器ｃが溝形部材１１ａを検知しなくなり、溝形部材１１ｂが搬送されてくるのを待つ状態となる。
その後、溝形部材１１ｂ、１１ｃ・・が本設備によって連続して加工され、製品取り出し口３５まで運搬されるが、先行する溝形部材１１と後続する溝形部材１１は加工中にぶつかることはない。
【００４６】
製品取り出し口３５から、リフトカー、ホイスト等によって取り出された溝形部材１１は、孔加工時に発生したドロス等の後処理や製品検査を経て出荷される。以上のような工程によって、品質の安定した製品を連続して製造することができるようになった。
【００４７】
なお、本発明は前記実施の形態に限定されるものではなく、例えば、孔加工手段は、複数設けてもよい。本実施の形態での孔加工にかかった時間は、８０〜１６０秒程度で、プレス加工にかかった時間は、５０秒程度であり、このため、プレス装置が作業していない時間が多かった。このため、孔加工時間を短くするためには、上記のように孔加工手段である多関節ロボットを増やすことも可能である。また、反転装置の稼働時間中に他の作業ができないという問題点も考慮に入れると、プレス装置の左右両側から、孔加工が終了した溝形部材を投入すると、さらに効率よく製造ができる。
【００４８】
【発明の効果】
請求項１〜９記載の鋼製枕木の連続製造設備においては、前部に複数の溝形部材を蓄える第１のコンベアが設けられているので、一時に多数の溝形部材を第１のコンベア上に積載しておくことができ、時間的な効率がよい。
さらに、第１のコンベアによって搬送された溝形部材を個々に取り出すことができるので、それぞれの装置上での溝形部材がぶつかることを防ぎ連続的に安定して製造できる。
また、孔加工作業台に載った溝形部材を所定位置に位置合わせを行う第１の位置決め装置を有しているので、短時間で製造でき、品質を安定させることができる。
そして、進退可能となった仮受け装置を有しているので、横方向（溝形部材の長手方向）のどちらから搬送されてきても受け取ることができ、工場内の設置位置が限られる場合にも設置可能になる。また、横方向の両側から孔加工終了後の溝形部材を受け取りプレス加工を行うことによって、製造効率がよくなる。
孔加工作業台とプレス装置の間に、反転装置、中間載置台、第２のコンベア、仮受け装置を有しているので、孔開けと端曲げを連続的に行うことができる。
【００４９】
特に、請求項２記載の鋼製枕木の連続製造設備においては、孔加工手段は、多関節ロボットが、予め決定されたプログラムによって３次元的に制御するので、孔位置の変更に時間がかからず、正確に加工ができる。
請求項３記載の鋼製枕木の連続製造設備においては、孔加工作業台は、溝形部材の溝底部を上にして、溝底部の裏面を所定高さに保つ支持台を備えているので、孔加工時の高さ方向の位置のずれを板厚の公差の範囲内に抑えることができる。
請求項４記載の鋼製枕木の連続製造設備においては、第１の位置決め装置は、それぞれの押圧部材をロープを介して同期して引っ張り、溝形部材のセンタリングを行うエアシリンダーを有しているので、溝形部材の長さが一定していなくても中心位置を決めることができ、さらに長さが違う鋼製枕木を製造する場合でも位置決め装置の設定変更は少なくて済む。
また、カウンターウエイトを有しているので、エアシリンダーによるセンタリングの解除時に、エネルギーを消費せずに簡便に元の位置まで復帰させることができる。
【００５０】
請求項５記載の鋼製枕木の連続製造設備においては、第１のコンベアには、溝形部材の移動を個々に止める第１、第２のストッパーを有しているので、溝形部材を１本ずつ連続的に供給し、自動的に鋼製枕木の製造ができる。
請求項６記載の鋼製枕木の連続製造設備においては、反転装置は少なくとも２つの縦ローラを有しているので、溝形部材の横移動を防止すると共に、孔加工時には、幅方向の位置基準にもなり、また、溝形部材が縦方向に移動するときには、摺動による傷を防止することができる。
そして、溝形部材を上から押圧保持するパッドを有しているので、反転時のがたつきを防止して、製品の品質を向上させることができる。
請求項７記載の鋼製枕木の連続製造設備においては、中間載置台の昇降ローラは、固定ローラより上位位置に突出可能になっているので、溝形部材の幅方向と長手方向への移動を可能にし、迅速に製造ができる。
請求項８記載の鋼製枕木の連続製造設備においては、第２の位置決め装置は、溝形部材の幅方向のセンタリングを行う対となるガイド板を下型に有しているので、プレス加工中に同時に位置決めを行うことができ、また、ガイド板は移動しないので、補修が簡便に行える。
請求項９記載の鋼製枕木の連続製造設備においては、搬出装置は、リフト機構及び水平移動機構を有するので、金型との摺動による傷を防ぐことができ、迅速に移動可能となっている。
【図面の簡単な説明】
【図１】本発明の一実施の形態に係る鋼製枕木の連続製造設備の構成図である。
【図２】（Ａ）、（Ｂ）はそれぞれ同第１のコンベアの側面図、正断面図である。
【図３】同第１のコンベア、中間載置台を示す側断面図である。
【図４】同反転装置を示す平面図である。
【図５】同反転装置を示す正断面図である。
【図６】同幅方向調整装置を示す平面図である。
【図７】同幅方向調整装置を示す正面図である。
【図８】同第１の位置決め装置を示す右側面図である。
【図９】同中間載置台を示す平面図である。
【図１０】（Ａ）、（Ｂ）はそれぞれ同中間載置台の右側面図、正面図である。
【図１１】同プレス装置の正面図である。
【図１２】（Ａ）、（Ｂ）はそれぞれ同プレス装置の左側面図、同プレス装置と溝形部材の位置関係を示す部分左側面図である。
【図１３】（Ａ）、（Ｂ）はそれぞれ同プレス装置と第２の位置決め装置の正面図、同プレス装置と第２の位置決め装置の左側面図である。
【図１４】（Ａ）、（Ｂ）はそれぞれ同第３のコンベアの搬出装置の部分平面図、正断面図である。
【図１５】（Ａ）〜（Ｅ）はそれぞれ従来例に係る鋼製枕木（ＡＰ型）の平面図、同（ＡＰ型）の正面図、同（ナブラ型）の平面図、同（ナブラ型）の正面図、同（ＡＰ型、ナブラ型）の側断面図である。
【符号の説明】
１０鋼製枕木の連続製造設備１１溝形部材
１１ａ角部１２溝底部
１３前部１４第１のコンベア
１５中間載置台１６孔加工作業台
１７反転装置１８第１の位置決め装置
２０孔加工手段２１第２のコンベア
２２プレス加工位置２３仮受け装置
２４下金型２５下金型
２６受け台２７下型
２８上金型２９上金型
３０押圧台３１上型
３２プレス装置３４搬出装置
３５製品取り出し口３６第３のコンベア
３７プレート３８プレート
３９ローラ４０側端部
４１第１のストッパー４２第２のストッパー
４３ストッパー片４４ストッパー片
４５アーム４６エアシリンダー
４７ピストンロッド４８前端部
４９ホイールコンベア( 固定ローラ)
５０押し出し部材（プッシャ）５１回転軸
５２右側部５３復帰錘
５４上側部５５エアシリンダー
５６縦ローラ５７反転軸
５８保持部材（金物）５９軸受
６０駆動モータ（回転駆動源）６１パッド
６２シリンダー６３開口部
６４補助ローラ６５固定軸
６６短軸６６ａ軸受
６７ブラケット６８ピストンロッド
６８ａ取付け金具６９シリンダー
７０底内側部７１上側部
７２受けローラ（支持台）７３軸受
７４受けローラ軸７５幅方向調整装置
７６支持軸７７軸受
７８腕部材７９腕部材
８０ブラケット８１軸
８２押圧ローラ８３シリンダー
８４押圧部材８４ａ台
８５押圧部材８５ａ台
８６ロープ８７ロープ
８８エアシリンダー８９カウンターウエイト
９０カウンターウエイト９１ピストンロッド
９２ブラケット９２ａ台
９３プーリ９４プーリ
９５プーリ９６端面
９７端面９８解除ロープ
９９解除ロープ１００昇降ローラ
１００ａ駆動チェーン１００ｂ駆動チェーン
１００ｃ駆動チェーン１００ｄ駆動チェーン
１００ｅ駆動チェーン１００ｆ駆動チェーン
１００ｇ駆動チェーン１００ｈ駆動チェーン
１００ｉ駆動チェーン１０１昇降台
１０１ａ基台１０２移動モータ
１０３昇降シリンダ１０４ロッド
１０５回動ブラケット１０６水平軸
１０７回動腕１０８支持軸
１０９支持ローラ１１０保持腕
１１１保持台１１２スプロケット
１１３固定台１１４エアシリンダー
１１５移動台１１６シリンダー
１１７仮受け台１１８仮受けローラ
１１９第２の位置決め装置１２０溝側部押圧機構
１２０ａロープ１２１溝側部押圧機構
１２１ａロープ１２２エアシリンダ−
１２３カウンターウエイト１２４カウンターウエイト
１２５テーパローラ１２５ａ上端部
１２６ガイドローラ１２７爪部
１２８爪部１３０爪部
１３１爪部１３３爪
１３４爪１３５リフト機構
１３６水平移動機構１３７エアシリンダー
１３８水平腕部１３９連結部材
１４０固定部材１４１水平連結腕
１４２チェーンコンベア１４３駆動手段[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a manufacturing facility for steel sleepers used in railways and the like, and more particularly to a continuous manufacturing facility for steel sleepers that continuously performs hole processing and end bending processing of sleepers.
[0002]
[Prior art]
In recent years, steel sleepers have come to be used due to the high price of wooden sleepers due to depletion of wood resources and the difficulty of disposal of concrete sleepers, and various forms have been developed and put into practical use.
The steel sleepers 200 and 201 shown in FIGS. 15 (A) to 15 (E) are provided with rail mounting holes 205 at predetermined positions of the groove bottom portions 203 and 204 of the steel channel members 202 and 202a cut to a predetermined length. , 206 and 207, and both end portions 208, 208a, 209 and 210 are subjected to end bending. The rail mounting holes 205, 206, and 207 have various shapes depending on the shape of the fastening plate to be attached to them. For example, an AP type using a bolt and a nut or a nabler type (mounting holes 205, 206), a bolt And a band roll type (mounting hole 207) using a locking member that does not use a nut. The shape of the both ends 208, 208a, 209, 210 is such that when the groove bottom portions 203, 204 of the groove-shaped members 202, 202a are turned up, the shape is bent downward and widened to a certain width in the width direction. It is formed so that the lateral resistance force is increased.
[0003]
Conventionally, when manufacturing a steel sleeper, first, a grooved member is placed on a drilling work table one by one by a manual lift truck or hoist, and drilling is performed. Alternatively, it was removed from the drilling work table by a hoist and accumulated on a temporary table.
Then, after the drilling operation is finished, the groove-shaped members are placed one by one from the temporary table on the press device by manual lift truck or hoist and subjected to end bending, and then again by the manual press lift truck or hoist. Had been removed from. After that, it was shipped through post-processing such as deburring and product inspection. Through this manufacturing process, a product with a predetermined shape could be produced. In particular, when many small-lot products were made, the equipment was changed little and the cost was saved.
[0004]
[Problems to be solved by the invention]
However, in recent years, with the increase in the production amount of steel sleepers, the shape of steel sleepers has been refined and unified as a general shape, so it has become necessary to produce a large amount of products at once.
In the conventional steel sleeper manufacturing equipment, the production efficiency is low when producing a large quantity of products, and the quality is not stable because the work is carried out manually when setting the member on the work table or device. There was a problem.
The present invention has been made in view of such circumstances, and an object thereof is to provide a continuous manufacturing facility for steel sleepers capable of continuously performing drilling and end bending and stabilizing the quality. .
[0005]
[Means for Solving the Problems]
The steel sleeper continuous manufacturing facility according to claim 1, which meets the above-mentioned purpose, is a steel in which a rail mounting hole is formed in a groove-shaped member cut to a predetermined length, and end bending is performed on both sides by a press device. A sleeper manufacturing facility, wherein the groove-shaped member is conveyed with the groove bottom facing down, and a plurality of the groove-shaped members are stored in a front portion, and the first conveyor conveys the groove-shaped member. An intermediate mounting table for taking out and temporarily placing the groove-shaped members individually, and placing the groove-shaped member mounted on the intermediate mounting table on the hole working table by inverting it or placing it on the hole working table A reversing device for reversing and placing the grooved member that has been drilled on the intermediate mounting table again, and a first positioning for aligning the grooved member placed on the hole working table at a predetermined position. An apparatus and the groove positioned on the drilling workbench A hole processing means for drilling the rail mounting hole in the member, and the groove member mounted on the intermediate mounting table in the longitudinal direction of the groove member until the press processing position is completed after the hole processing is completed. A second conveyor that conveys, a temporary receiving device that can move back and forth, and a groove-shaped member that has been conveyed by the second conveyor to the pressing position; and the pressing position. A lower die having a lower die on both sides, a lower die having a cradle in the center, and an upper die having a upper die on both sides corresponding to these, and a pressing die in the center; and A second positioning device for aligning the groove-shaped member placed on the press device at a predetermined position; and a carry-out device for removing the groove-shaped member placed on the press device from the press device after the press work is completed. , By the unloading device Ri said channel members issued and a third conveyor for unloading the product outlet.
[0006]
The continuous manufacturing equipment for steel sleepers according to claim 2 is the continuous manufacturing equipment for steel sleepers according to claim 1, wherein the hole drilling means is an articulated robot and a program determined in advance by the articulated robot. And a device attached to the plasma torch which is controlled three-dimensionally.
The continuous manufacturing equipment for steel sleepers according to claim 3 is the continuous manufacturing equipment for steel sleepers according to claim 1 or 2, wherein the drilling work table has the groove bottom of the channel-shaped member facing upward, A support base for keeping the back surface of the groove bottom at a predetermined height is provided.
The continuous manufacturing equipment for steel sleepers according to claim 4 is the continuous manufacturing equipment for steel sleepers according to claim 3, wherein the first positioning device is configured such that the groove-shaped member is freely movable in the longitudinal direction. A support base, a pressing member provided facing each of the outer sides in the longitudinal direction of the groove-shaped member resting on the support base, and pulling each pressing member synchronously via a rope; An air cylinder that performs centering of the groove member, and a counterweight that biases the pressing member outward in the longitudinal direction of the groove member when the centering by the air cylinder is released.
[0007]
The continuous manufacturing equipment for steel sleepers according to claim 5 is the continuous manufacturing equipment for steel sleepers according to any one of claims 1 to 4, wherein the first conveyor is on the first conveyor. First and second stoppers that are attached to the front part in the moving direction according to the width of the channel member and individually stop the movement of two adjacent channel members that move laterally on the first conveyor. And the second stopper on the rear side is operated to release the first stopper on the front side, so that only one of the channel members is conveyed as it is by the first conveyor.
The continuous manufacturing equipment for steel sleepers according to claim 6 is the continuous manufacturing equipment for steel sleepers according to any one of claims 1 to 5, wherein the reversing device is superposed at the lower portion with the intermediate mounting table. At least two vertical rollers for stopping the lateral movement of the groove-shaped member conveyed into the hardware by the first conveyor or the pusher following the groove-shaped member arranged in the U-shaped hardware, A pad that fits into the hardware and presses and holds the groove-shaped member that is in contact with the vertical roller from above, and the groove-shaped member held by the pad together with the hardware centered on the base end portion of the hardware And a rotational drive source that rotates 180 degrees.
[0008]
The continuous manufacturing equipment for steel sleepers according to claim 7 is the continuous manufacturing equipment for steel sleepers according to claim 6, wherein the intermediate mounting table includes a fixing roller that conveys the groove-shaped member in the width direction, and the fixing device. It has a lifting roller that can project to a higher position than the roller and moves the mounted groove-shaped member in the longitudinal direction.
The continuous manufacturing equipment for steel sleepers according to claim 8 is the continuous manufacturing equipment for steel sleepers according to any one of claims 1 to 7, wherein the second positioning device has a width of the groove-shaped member. The lower mold has a pair of guide plates that perform direction centering.
The continuous manufacturing equipment for steel sleepers according to claim 9 is the continuous manufacturing equipment for steel sleepers according to any one of claims 1 to 8, wherein the carry-out device includes the lower molds on the both sides and the center. A lift mechanism and a horizontal movement mechanism are provided in which a claw at the front part enters between the cradle and the groove-shaped member after the press working is lifted from the bottom and moved horizontally to be taken out.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the accompanying drawings to provide an understanding of the present invention.
As shown in FIG. 1, a steel sleeper continuous manufacturing facility 10 according to an embodiment of the present invention has a groove-shaped member 11 with a groove bottom portion 12 of a groove-shaped member 11 cut into a predetermined length facing downward. The first conveyor 14 that stores the plurality of channel members 11 in the front portion 13 and the channel members 11 that are transported by the first conveyor 14 are individually taken out and temporarily placed for hole processing. The intermediate mounting table 15 is provided. When a plurality of the groove members 11 are placed on the first conveyor 14 by a lift car or the like, the first conveyor 14 senses the front work situation with a sensor or the like and continuously feeds the groove members 11.
The predetermined length here refers to a length necessary for producing a steel sleeper, for example, a length of 2000 to 3000 mm.
[0010]
Then, the steel sleeper continuous production equipment 10 inverts the groove-shaped member 11 placed on the intermediate placing table 15 and places it on the hole working table 16 or is placed on the hole working table 16 to perform hole machining. A reversing device 17 for reversing and placing the completed groove member 11 on the intermediate mounting table 15, a first positioning device 18 for aligning the groove member 11 placed on the hole processing work table 16 at a predetermined position, and a hole The groove member 11 positioned on the processing work table 16 is provided with hole processing means 20 for processing a hole for the rail mounting hole to perform the hole processing. The quality of the steel sleepers is made uniform by automatically placing, positioning and drilling on the drilling work table 16.
The predetermined position here refers to the center position in the longitudinal direction of the channel member.
[0011]
Furthermore, the steel sleeper continuous manufacturing equipment 10 is reversed again by the reversing device 17 after the hole processing is finished, and the groove-shaped member 11 placed on the intermediate mounting table 15 is moved to the position before the press-working position 22. And the second conveyor 21 that is transported in the longitudinal direction, and the channel member 11 that is capable of moving forward and backward and is transported up to the press processing position 22 by the second conveyor 21 is temporarily placed on the press processing position 22. A receiving device 23, a lower mold 27 provided at a pressing position 22 and having lower dies 24 and 25 on both sides and a receiving base 26 in the center, and as shown in FIG. A pressing device 32 having an upper die 31 having a pressing table 30 in the center for the dies 28 and 29, and a second positioning device (not shown) for aligning the groove member 11 mounted on the pressing device 32 at a predetermined position. press Perform a factory. Transport to the press position and position adjustment are also performed automatically.
The predetermined position here refers to the center position in the longitudinal direction of the channel member.
In the continuous manufacturing equipment 10 for the steel sleepers after the press work is finished, the carry-out device 34 for taking out the groove-shaped member 11 mounted on the press device 32 from the press device 32, and the groove-shaped member 11 taken out by the carry-out device 34 as a product. Continuous production is carried out by carrying out the product by the third conveyor 36 carried out to the take-out port 35. These will be described in detail below.
[0012]
As shown in FIGS. 1 and 2, the first conveyor 14 uses, for example, a chain conveyor. A roller 39 is attached to the chain via plates 37 and 38 to facilitate movement of the channel member 11.
In addition, although the groove-shaped member 11 is conveyed with the groove bottom part 12 facing down, it can also be conveyed with the groove bottom part 12 facing up. In this case, the side end portion 40 of the groove-shaped member 11 may be inserted between the adjacent plates 37 of the chain conveyor and cannot be removed. Therefore, the plates 37 and 38 and the roller 39 are removed, and a slat or the like is attached instead. It is good to use. In addition, a plurality of channel members 11 can be stored on the first conveyor 14, and in the present embodiment, it is possible to store up to about 13. When it is desired to increase the number to be stored, the length of the first conveyor 14 in the moving direction may be increased.
[0013]
As shown in FIG. 1 and FIG. 2 (A), it is attached to the front portion 13 in the moving direction on the first conveyor 14 in accordance with the width of the groove-shaped member 11, and moves laterally on the first conveyor 14. First and second stoppers 41 and 42 for individually stopping the movement of two adjacent channel members 11 are provided. As shown in FIG. 2 (B), the first stopper 41 is configured such that the stopper pieces 43 and 44 that are rotatably attached in the direction orthogonal to the traveling direction of the first conveyor 14 are air-operated via the arm 45. A link mechanism that is simultaneously rotated by the cylinder 46 is configured. The first conveyor 14 is always in operation during the operation of the continuous manufacturing equipment 10 for steel sleepers, and the movement / stop of the groove-shaped member 11 is managed by the first and second stoppers 41 and 42. .
When the air cylinder 46 is actuated, the piston rod 47 protrudes, and the stopper pieces 43 and 44 rotate to protrude above the upper surface of the first conveyor 14, thereby stopping the channel member 11. Can do. When the operation is released, the piston rod 47 returns to the original position, and the stopper pieces 43 and 44 are rotated to the position of the two-dot chain line in the figure below the upper surface of the first conveyor 14, The shape member 11 moves forward in the flow direction of the first conveyor 14. Although the side view of the second stopper 42 is not shown, it has the same shape as the first stopper 41.
[0014]
A detector (not shown) is provided at an intermediate position between the first and second stoppers 41 and 42, thereby confirming the position of the groove-shaped member 11 and controlling the movement of the first and second stoppers 41 and 42. be able to.
[0015]
The operation of the first and second stoppers 41 and 42 is performed as follows.
A detector (hereinafter referred to as detector a) provided on the first conveyor 14 and a second stopper 42 are interlocked, and a detector (hereinafter referred to as detector b) provided on the intermediate mounting table 15 in front. And the first stopper 41 are also interlocked.
When the continuous production equipment 10 for steel sleepers is in operation, the plurality of channel members 11 on the first conveyor 14 are sequentially sent forward. When the detector a detects the groove member 11 (when a detection signal is sent (the same applies hereinafter)), the groove behind the groove member 11 detected by the detector a by the second stopper 42. The shape member 11 is stopped. When the detector a does not detect the preceding groove member 11, the second stopper 42 is released and the groove member 11 moves forward. When the detector b detects that the groove-shaped member 11 is on the intermediate mounting table 15, the groove-shaped member 11 on the rear side of the groove-shaped member 11 detected by the detector b by the first stopper 41 is It can be stopped. At this time, since the detector a is also detected as the preceding groove member 11, the second stopper 42 is also operated, and the subsequent groove member 11 is stopped by the second stopper 42.
When the work on the intermediate mounting table 15 is finished and the detector b no longer detects the groove-shaped member 11 on the intermediate mounting table 15, the first stopper 41 is released, and only one groove-shaped member 11 is provided. It can be conveyed to the front part 13 by the first conveyor 14.
[0016]
When the first stopper 41 is released, the groove-shaped member 11 is carried to the front end 48 of the first conveyor 14 as shown in FIG. 3, and is flush with the top surface of the first conveyor 14 from the front end 48. It stops in a state where it rides on a wheel conveyor 49 which is an example of a fixed roller provided up to the intermediate mounting table 15. Although the number of rows of the wheel conveyor 49 is arbitrary, in this embodiment, the number is two. Thereby, it can convey, without scratching the surface of the channel member 11.
[0017]
When the first conveyor 14 is viewed from the side, an extrusion member 50 that is an example of a pusher is provided at a position where it overlaps with the second stopper 41. The extruding member 50 is a metal member having a substantially L-shape when viewed from the side of the first conveyor 14, and a bent portion near the center is inside the first conveyor 14 and has a groove shape. Two or more are rotatably attached to a rotating shaft 51 provided in the longitudinal direction of the member 11. On the upper side from the bent portion, an upper portion 54 that can protrude above the first conveyor 14 is provided, and on the right side from the bent portion, a right side portion 52 having a return weight 53 at the tip thereof is provided. ing.
When the groove-shaped member 11 moves above the push-out member 50, the push-out member 50 is pushed by the upper portion 54 from the right direction and rotates approximately 15 degrees counterclockwise until the position of the two-dot chain line in the figure. Since it rotates, the groove-shaped member 11 passes the upper side of the rotated pushing-out member 50, and movement is not prevented. Further, due to the weight of the return weight 53, the pushing member 50 can rotate clockwise after passing through the groove-shaped member 11, and can automatically return to the position of the solid line in the drawing.
[0018]
The pushing member 50 is connected to the air cylinder 55 and can move in the same direction as the moving direction of the first conveyor 14. When the groove-shaped member 11 passes over the push member 50 and then partially rides on the wheel conveyor 49, the push member 50 is pushed toward the intermediate mounting table 15 by the air cylinder 55. The pushing member 50 which has returned to the original state is pushed and moved by the upper portion 54 protruding above the first conveyor 14 until the entire groove-shaped member 11 is positioned on the intermediate mounting table 15. As shown in FIGS. 3 to 5, on the intermediate mounting table 15, a part of the reversing device 17 is made of metal (metal) having a U-shaped cross section, and a lower portion thereof is connected to the intermediate mounting table 15. A plurality of holding members 58 that are superposed and hold the groove-shaped member 11 at regular intervals open and wait for the opening 63, and the groove is formed by two or more vertical rollers 56 disposed therein. The lateral movement of the shape member 11 is stopped. The pushing member 50 is returned to its original position by the air cylinder 55 after the groove member 11 enters the reversing device 17.
[0019]
The reversing device 17 includes a reversing shaft 57 capable of reversing 180 degrees together with the holding member 58 in the middle of the intermediate mounting table 15 and the hole processing work table 16 provided in parallel with the intermediate mounting table 15 (the base end portion of the holding member 58). A plurality of holding members 58 are attached to the reversing shaft 57 in the axial direction of the reversing shaft 57 so as to be reversed about the base end portion thereof. Although the number of holding members 58 is two or more and arbitrary, it is set to 3 in the present embodiment. Two or more are required to suppress deformation of the channel member 11 due to twisting of the holding member 58 during reversal. Both ends of the reversing shaft 57 are supported by bearings 59. In addition, a drive motor 60, which is an example of a rotational drive source having the same shaft center as the reverse shaft 57, is connected to the outside of the bearing 59 on one side of the reverse shaft 57 via a shaft coupling.
In addition, a pad 61 that presses and holds the groove-shaped member 11 that is fitted into the holding member 58 and is in contact with the vertical roller 56 from above is reversed, and the groove-shaped member 11 held by the pad 61 is reversed by the drive motor 60. The holding member 58 rotates 180 degrees around the shaft 57. A cylinder 62 that moves the pad 61 up and down is provided on the upper portion of the holding member 58. The pad 61 is preferably made of a soft material so as not to damage the groove member 11. In this embodiment, a urethane product is used.
[0020]
An upper portion of the holding member 58 on the opening 63 side is attached via a bearing 66 a in which a short shaft 66 is paired in parallel with the axial direction of the reverse shaft 57 of the holding member 58. On the short shaft 66, a bracket 67 and a base portion of a fixed shaft 65 integrated with the bracket 67 at an angle of about 150 degrees are rotatably attached. An auxiliary roller 64 is rotatably attached to the fixed shaft 65, and an attachment fitting 68 a attached to the tip of the piston rod 68 is attached to the tip of the bracket 67. Is rotated about 60 degrees via the short shaft 66, and the auxiliary roller 64 opens and closes on the opening 63 side of the holding member 58.
By closing the opening 63 with the auxiliary roller 64, the groove-shaped member 11 can be prevented from popping out when the holding member 58 is reversed. Further, since the fixed shaft 65 of the auxiliary roller 64 in the closed state is parallel to the rotation shaft of the vertical roller 56, when the groove member 11 is conveyed in the longitudinal direction after completion of the hole processing, the position in the width direction is set. Deviation can be prevented.
[0021]
As shown in FIG. 3, the groove-shaped member 11 pushed out from the first conveyor 14 by the pushing member 50 moves on the wheel conveyor 49 until it comes into contact with the vertical roller 56. At this time, as shown in FIG. 5, the cylinder 69 is in the contracted state of the rod, the auxiliary roller 64 is in the position indicated by the two-dot chain line in the figure, and the holding member 58 is open. Thereafter, the cylinders 62 and 69 are actuated to hold the groove-shaped member 11 from above with the pad 61 and the auxiliary roller 64 closes the opening 63 of the holding member 58 (solid line portion in the figure).
The bottom inner part 70 of the holding member 58 is located at a position lower than the upper part 71 of the wheel conveyor 49. For this reason, when the pad 61 is pressing the side end portion 40 of the groove member 11, the groove bottom portion 12 of the groove member 11 presses not the bottom inner portion 70 of the holding member 58 but the upper portion 71 of the wheel conveyor 49. is doing. If this position relationship is maintained and reversed, the wheel conveyor 49 does not reverse, so that a gap is generated by a distance between the groove bottom portion 12 of the groove-shaped member 11 and the bottom inner portion 70 of the holding member 58. However, since the pressing force from the cylinder 62 is always transmitted to the groove member 11 through the pad 61 while the holding member 58 is reversed, the pad 61 is lowered by the gap, and the groove member 11 is moved down. Since the pressure is applied, no gap is generated during inversion.
By reversing the groove member 11 while pressing the groove member 11 with the pad 61, it is possible to prevent the groove member 11 from being damaged due to rattling.
[0022]
The groove-shaped member 11 is placed on the hole machining work table 16 after being inverted. As shown in FIG. 4, a receiving roller 72, which is an example of a support table that keeps the back surface of the groove-shaped member 11 at a predetermined height on the hole processing work table 16, avoiding the position of the holding member 58 of the reversing device 17. Are provided so as to be rotatable at two or more locations in the longitudinal direction of the groove-shaped member 11 to be set. The receiving roller 72 has a receiving roller shaft 74 held at both ends by a bearing 73 in the width direction of the groove-shaped member 11 with an interval of about 100 mm, and two or more rollers having a diameter of about 300 mm are attached rotatably. Yes. Further, the receiving roller 72 having a thickness of about 100 mm can be used, and conversely, the number can be three or more. Since the groove-shaped member 11 can be moved by the receiving roller 72 without sliding in the longitudinal direction, positioning in the longitudinal direction can be easily performed and no damage is caused.
The predetermined height here refers to a height for securing a necessary gap between the tool for performing the hole drilling means and the channel member.
[0023]
As shown in FIG. 6 and FIG. 7, the width direction adjusting device 75 is provided on the hole processing work table 16 on the front base as viewed from the first conveyor 14 of the hole processing work table 16. The support shaft 76 that is rotatable in parallel with the longitudinal direction of the support shaft 76, the bearing 77 that supports the end portions on both sides of the support shaft 76, and the support shaft 76 on both sides of the support shaft 76 avoiding the mounting positions of the bearing 77. The arm members 78 and 79 are provided on the outer side in the radial direction and substantially upward, and are rotatable together with the support shaft 76. Brackets 80 are provided at the tip portions of the arm members 78 and 79 in the direction of the drilling work table 16, and the bracket 80 is rotatable about the shaft 81 and the shaft 81 parallel to the arm members 78 and 79. And a pressure roller 82 attached to each other. A cylinder 83 is attached to the rear side of the arm member 79 and at a position lower than the upper end of the arm member 79 and avoiding the vicinity of the center of the support shaft 76.
[0024]
When the groove member 11 is placed on the hole machining work table 16 by the reversing device 17, the pressure applied to the groove member 11 via the pad 61 by the cylinder 62 is released. At this time, the cylinder 83 is in a state where the rod is contracted. The arm members 78 and 79 are supported in a state inclined about 15 degrees from the position perpendicular to the support shaft 76 toward the cylinder 83, and there is a gap between the pressing roller 82 and the groove-shaped member 11. Yes.
When the groove-shaped member 11 is placed on the hole machining work table 16 and the rod of the cylinder 83 is extended, the arm members 78 and 79 integrated with the support shaft 76 are rotated to a position where they are substantially vertical. At this time, the groove-shaped member 11 receives a pressing force from the cylinder 83 side by the pressing roller 82 and moves until it comes into contact with the vertical roller 56 mounted inside the reversing device 17. Thereby, the position of the channel-shaped member 11 in the width direction can be determined.
[0025]
The reason why the cylinder 83 is attached at a position away from the vicinity of the center of the support shaft 76 is that it does not interfere with the attachment position of the robot that performs hole machining. .
Further, the mounting position of the cylinder 83 in the height direction is also set to a position lower than the upper ends of the arm members 78 and 79 because this does not hinder the movement of the robot arm. As long as the movement of the robot is not hindered, the mounting height of the cylinder 83 is made substantially the same as the height of the groove member 11, and the rotation mechanism by the support shaft 76 and the arm members 78 and 79 is omitted and is linear. The groove-shaped member 11 can also be pressed.
[0026]
As shown in FIG. 8, the first positioning device 18 is mounted on the receiving roller 72 on which the groove-shaped member 11 placed on the hole drilling worktable 16 can freely move in the longitudinal direction, and on the receiving roller 72. The pressing members 84, 85 provided facing the both outer sides of the longitudinal direction of the groove-shaped member 11, and the pressing members 84, 85 are pulled inward synchronously via the ropes 86, 87, An air cylinder 88 for centering the shape member 11 and counterweights 89 and 90 for urging the pressing members 84 and 85 outward in the longitudinal direction of the groove shape member 11 when the centering by the air cylinder 88 is released. Yes.
The piston rod 91 of the air cylinder 88 protrudes in a normal state (when the centering is released). A bracket 92 is attached to the piston rod 91, and steel ropes 86 and 87, for example, are attached to the bracket 92. The directions of the ropes 86 and 87 are changed by pulleys 93, 94 and 95, and are attached to the inside of the pressing members 84 and 85. The length is adjusted so that the distance between the end surfaces 96 and 97 of the pressing members 84 and 85 is equal to the left and right from the center position S. The pressing members 84 and 85 and the bracket 92 are respectively attached to the bases 84a, 85a and 92a that can slide in the longitudinal direction of the channel member 11.
[0027]
The first positioning device 18 operates at the same timing as the width direction adjusting device 75 that performs positioning in the width direction. When the air cylinder 88 is actuated, the pressing members 84 and 85 are moved inward synchronously by the tensile force transmitted to the pressing members 84 and 85 via the ropes 86 and 87. One side in the longitudinal direction of the groove-shaped member 11 abuts on the pressing member 84 or 85 and moves inward together with the pressing member 84 or 85 as it is. When the other side in the longitudinal direction of the groove member 11 comes into contact with the pressing member 85 or 84 on the other side, the movement of the groove member 11 stops. At this time, the length from the center position S of the longitudinal direction of the groove-shaped member 11 to both ends is equal. Even when there is an error in the length of the channel-shaped member 11, the position can be adjusted based on the center.
Even when the sleepers having different lengths are manufactured, the pressing members 84 and 85 are respectively attached to the slidable bases 84a, 85a, and 92a, so that the adjustment can be easily performed.
[0028]
When the operation of the air cylinder 88 is released after the work is finished, the ropes 86 and 87 are loosened, and the tensile force to the inside of the pressing members 84 and 85 is also released. Since the pressing members 84 and 85 are moved by applying a biasing force to the outside by the counterweights 89 and 90 attached via the release ropes 98 and 99 attached to the outside of the pressing members 84 and 85, the groove shape The fixing of the member 11 to both ends in the longitudinal direction is released.
In the present embodiment, the air cylinder 88 is used to fix the groove-shaped member 11, but the pressing members 84, 85 on both sides from the motor via, for example, screws each having a thread groove cut in the opposite direction. Even if the driving force is transmitted to the center position, the center position can be similarly adjusted. In this case, the counterweights 89 and 90 can be omitted because they can be released by rotating the motor in the reverse direction.
[0029]
As shown in FIG. 1, the hole drilling means 20 is performed by an articulated robot, a plasma torch controlled three-dimensionally by a program determined in advance by the articulated robot, and equipment attached thereto. The groove-shaped member 11 positioned and fixed by the above procedure is fixed with the groove bottom portion 12 on the upper side and the back surface of the groove bottom portion 12 with the receiving roller 72 as a reference in the height direction. Since the positional deviation in the height direction is within the range of the dimensional tolerance of the thickness of the channel member 11, it can be processed with high accuracy.
As the position and shape of the hole processing, for example, the rail mounting holes 205 to 207 shown in the conventional examples of FIGS. 15A and 15C are programmed in advance, so that the hole processing can be automatically performed. . Dross is generated on the back surface of the groove bottom portion 12 of the groove-shaped member 11 processed by the plasma torch, but it can be easily dropped because it is a small amount compared to the return generated when hole processing is performed, for example, by pressing. The position of the arm of the articulated robot before and after the operation is such that it does not overlap with the drilling work table 16, and when the reversing device 17 malfunctions, the grooved member 11 collides with the arm of the articulated robot. Prevents damage.
[0030]
After completion of the hole processing, the cylinder 62 of the reversing device 17 is operated and the groove member 11 is pressed by the pad 61. And it reverses again and the channel-shaped member 11 is mounted on the intermediate mounting base 15, and the press by the cylinder 62 is cancelled | released.
As shown in FIGS. 9, 10A, and 10B, an upper portion of the intermediate mounting table 15 has a wheel conveyor 49 that can be moved in the width direction in the same manner as before the hole processing. The member 11 is placed on the wheel conveyor 49.
The intermediate mounting table 15 has a wheel conveyor 49 that conveys the groove member 11 in the width direction, and an elevating roller 100 that can project to a higher position than the wheel conveyor 49 and moves the mounted groove member 11 in the longitudinal direction. And have. The elevating roller 100, the elevating platform 101 with the elevating roller 100 connected to the upper portion, and the moving motor 102 that drives the elevating roller 100 provided at the lower portion on one side in the longitudinal direction of the elevating platform 101 are integrated. It is provided so that it can move up and down.
[0031]
A lifting cylinder 103 and a rod 104 that operates in conjunction with the lifting cylinder 103 are attached to the base 101a with the same longitudinal direction as that of the lifting base 101. A plurality of horizontal shafts 106 that are orthogonal to the direction in which the rod 104 attached to the lifting cylinder 103 operates are provided on the base 101a via bearings below the lifting platform 101, and the rod 104 and the horizontal shaft 106 rotate. The horizontal shaft 106 is connected by a bracket 105 and is attached to be rotatable according to the movement of the rod 104. A rotating arm 107 that can rotate integrally with the horizontal shaft 106 is attached to both ends of the horizontal shaft 106, and a support roller 109 is attached to a support shaft 108 that is attached to the tip of the arm. Yes. The lifting platform 101 is supported by the support rollers 109 attached to the respective support shafts 108, and the height is determined.
[0032]
When the hole processing is completed and the groove member 11 is placed on the intermediate placing table 15 by the reversing device 17, the lifting cylinder 103 is operated, and the protruding rod 104 is pulled in the direction of the lifting cylinder 103. The rod 104 receives the force at the tip of the rotating bracket 105, and the horizontal shaft 106 rotates. The lift 101 is lifted and mounted on the lift 101 by a support roller 109 that has the same height as the horizontal shaft 106 and pivots about the horizontal shaft 106 in the upward direction of the horizontal shaft 106. The height of the lifting roller 100 is higher than the height of the wheel conveyor 49, and the channel member 11 is supported by the lifting roller 100. The other side of the lifting platform 101 is connected to the holding platform 111 via the holding arm 110 and a pivot shaft provided on both sides thereof. This restricts excessive movement of the lifting platform 101 in the lateral direction.
[0033]
The elevating roller 100 is driven by a moving motor 102, and is connected by drive chains 100a to 100i shown in FIG. 10A via sprockets 112 mounted between the elevating rollers 100 at substantially the same height as the elevating platform 101. Has been. Since the raising / lowering roller 100, the moving motor 102, and the sprocket 112 are moved up and down together, the drive chains 100a to 100i do not loosen. Moreover, since the raising / lowering roller 100 is driven by the sprocket 112 provided at a position lower than the raising / lowering roller 100 and the drive chains 100a to 100i, it does not interfere with the wheel conveyor 49 during raising and lowering.
The groove-shaped member 11 supported by the elevating roller 100 is supported at a higher position than when it is supported by the wheel conveyor 49 as shown by a two-dot chain line in FIG. Since the gap in the height direction 58 is sufficiently secured, the holding member 58 and the groove-shaped member 11 do not collide with each other at the time of raising and lowering and are not damaged.
The groove-shaped member 11 supported on the elevating roller 100 confirms that there is no preceding groove-shaped member 11 on the pressing device 32 (see FIGS. 11 and 12) in the next process, and then the moving motor 102. Can be moved by the driving force transmitted to the lifting roller 100.
[0034]
The second conveyor 21 shown in FIG. 1 is driven in synchronization with the moving motor 102 of the intermediate mounting table 15, and conveys the channel member 11 to the temporary receiving device 23 that has advanced from the intermediate mounting table 15 to the press working position 22. . Since a guide roller (not shown) is provided on the left and right of the movement direction of the groove member 11 with a gap through which the groove member 11 passes, a lateral displacement during transportation can be prevented.
[0035]
As shown in FIGS. 1, 11, and 12 (A), the temporary receiving device 23 is retracted backward when the press device 32 is operated.
The temporary receiving device 23 has a fixed base 113 with rails in a direction movable in the width direction of the groove-shaped member 11, and has a moving base 115 that can be advanced by an air cylinder 114 on the upper part thereof. A temporary receiving table 117 that can be moved up and down by a cylinder 116 is attached to the moving table 115. A plurality of temporary receiving rollers 118 are provided at the lower portion of the temporary receiving table 117, and the height position H1 is usually the same as that of the second conveyor 21.
Since the height position H1 of the groove-shaped member 11 conveyed from the second conveyor 21 is higher than the height position H2 of the lower molds 24, 25, the press device avoids contact with the lower molds 24, 25. It can be conveyed to the vicinity of 32 pressing positions. After being conveyed to the vicinity of the press working position, the groove-shaped member 11 is lowered by the cylinder 116 to the height position H3 lower than the height position H2 of the lower molds 24, 25 and placed on the lower molds 24, 25. The
[0036]
The lateral displacement can be prevented by the taper roller 125 and the guide roller 126 provided with a gap when the groove member 11 is conveyed.
As shown in FIG. 12 (B), a taper that matches the angle with the corner 11 a of the groove-shaped member 11 is formed on the circumferential portion of the taper roller 125. When the groove member 11 is conveyed to a predetermined position and then lowered to the height H3 as shown in FIG. 11, the position of the upper end portion 125a of the taper roller 125 is also lowered from the lower surface of the groove portion 12 of the groove member 11. When the air cylinder 114 is operated and the moving table 115 is lowered to the rear of the press device 32 (position shown in FIG. 12A), it does not hit the channel member 11.
[0037]
The groove-shaped member 11 can be positioned in the longitudinal direction by the second positioning device 119 shown in FIGS. 13 (A) and 13 (B). The second positioning device 119 is provided on both sides of the rear portion of the pressing device 32 at a position that does not interfere with the vertical movement of the pressing device 32 and the longitudinal movement of the temporary receiving device 23. The second positioning device 119 includes groove side portion pressing mechanisms 120 provided to face the outer sides in the longitudinal direction of the groove member 11 placed on the lower molds 24 and 25 of the press device 32, respectively. 121, an air cylinder 122 that pulls the groove side portion pressing mechanisms 120 and 121 synchronously via the ropes 120a and 121a to center the groove-shaped member 11, and a groove side when the centering by the air cylinder 122 is released. There are counterweights 123 and 124 for urging the part pressing mechanisms 120 and 121 to the rear of the pressing device 32, respectively.
[0038]
The groove side pressing mechanisms 120 and 121 constitute a link mechanism composed of a plurality of parts. When the air cylinder 122 is operated, the claw portions 127 and 128 attached to the front portions of the left and right groove side pressing mechanisms 120 and 121 press the groove-shaped member 11 in synchronization with the attached ropes 120a and 121a. At this time, the claw portions 127 and 128 press only the side portion on one side in the width direction of the groove-shaped member 11 as shown in FIG. Further, since the lower molds 24 and 25 on which the groove member 11 is placed are rotatable and do not slide at the time of positioning, the groove member 11 is not damaged.
After positioning in the longitudinal direction, the centering is released by the air cylinder 122. The groove side portion pressing mechanisms 120 and 121 are link mechanisms that rotate around the vertical axes near the both ends of the groove member 11 pressed by the claw portions 127 and 128, Since it moves to (behind the press apparatus 32), subsequent press work and conveyance of the subsequent groove-shaped member 11 are not disturbed.
[0039]
The attachment positions of the claw portions 127 and 128 can be changed. For example, by changing to the positions of the claw portions 130 and 131, it is possible to cope with the manufacture of steel sleepers having different lengths.
When the upper mold 31 of the pressing device 32 is lowered, the upper molds 28 and 29 press the upper portions on both sides in the longitudinal direction of the channel member 11. Since the lower portions on both sides of the groove-shaped member 11 are supported by the lower molds 24 and 25, the inside thereof is pressed from above. The upper molds 28 and 29 are pressed as they are, and the both end portions are bent until the central portion of the groove-shaped member 11 comes into contact with the cradle 26. At this time, the second positioning device 119 includes a guide plate (not shown) that performs centering in the width direction of the groove member 11 on both sides of the groove member 11 in the width direction of the cradle 26 in the lower mold 27. The gap between the two guide plates is formed to be substantially the same as the width of the channel-shaped member 11, and the two guide plates, the central pressing table 30 and the receiving table 26 prevent positional deviation in the width direction during end bending. can do.
After the end bending process, the upper die 31 is raised to the original position, and the press process is completed.
[0040]
In the carry-out device 34 shown in FIGS. 14A and 14B, the front claws 133 and 134 enter between the lower molds 24 and 25 of the press device 32 and the cradle 26, and the press work is finished. After the channel-shaped member 11 is lifted from the bottom, it has a lift mechanism 135 and a horizontal movement mechanism 136 that are horizontally moved and taken out. The lift mechanism 135 is provided on the lower side of the third conveyor 36 on the side of the press device 32 and has claws 133 and 134 and a horizontal arm portion 138 to which the lift mechanism 135 is attached. It is attached to an air cylinder 137 operable in a direction. The horizontal movement mechanism 136 can translate the fixing member 140 attached to the air cylinder 137 of the lift mechanism 135, the horizontal connection arm 141 connected to the fixing member 140, and the movement direction of the third conveyor 36. Drive means 143 (for example, having a motor and a gear box) shown in FIG. 1 provided on the outlet side of the third conveyor 36, and the moving direction of the third conveyor 36 below the fixed member 140. It is placed on a chain conveyor 142 which is an example of a moving means provided in parallel.
[0041]
After the press work is finished, the horizontal connecting arm 141 protrudes in the direction of the press device 32 by the driving means 143. As a result, the connecting member 139 moves on the chain conveyor 142 from the position indicated by the two-dot chain line in FIG. 14B to the position indicated by the solid line. Then, the entire lift mechanism 135 moves in the direction of the pressing device 32, and the claws 133 and 134 at the front part enter below the pressed channel member 11 on the pressing device 32. Next, when the air cylinder 137 is operated, the connecting member 139, the horizontal arm portion 138, and the claws 133 and 134 of the lift mechanism 135 are moved to the upper portions, respectively, and thereby the bottom portion of the groove-shaped member 11 (the claws 133 and 134). The supporting position is on the press device 32 and is lifted to the position of the two-dot chain line in the figure. Then, in this state, the horizontal connecting arm 141 is returned to the original position by the driving means 143, and the groove member 11 is moved onto the third conveyor 36 indicated by the two-dot chain line in the drawing. When the air cylinder 137 is protruded in this state, the channel member 11 supported by the claw portions 133 and 134 is placed on the third conveyor 36. Since the third conveyor 36 is always operating during the operation of the continuous production equipment 10 for steel sleepers, the groove member 11 placed thereon is conveyed to the product take-out port 35. A drop guide (not shown) is attached to the product outlet 35 to prevent the groove member 11 from dropping.
[0042]
Next, processing of the channel member 11 will be described along each step. Here, the groove-shaped member 11 is a groove-shaped member 11a, a groove-shaped member 11b, a groove-shaped member 11c,.
Up to the first conveyor 14, the channel member 11 can be placed by a lift car, a hoist, or human power. When the groove-shaped members 11a, 11b, 11c,... Are placed on the first conveyor 14 with the groove bottom portion 12 facing down, they move forward on the first conveyor 14 shown in FIG. The conveyance speed of the first conveyor 14 is arbitrary, but in the present embodiment, it is about 10 m / min. The first and second stoppers 41 and 42 are configured such that the detector a provided between the first and second stoppers 41 and 42 and the detector b provided on the intermediate mounting table 15 detect the groove-shaped member. Therefore, the channel member 11a passes without stopping at the position of the second stopper 42.
[0043]
When the channel member 11a passes the detector a, the second stopper 42 detects the channel member 11a and stops the channel member 11b and the subsequent members.
The groove-shaped member 11a also passes through the position of the first stopper 41 and moves onto the intermediate mounting table 15. And the 1st stopper 41 detects the groove-shaped member 11a with the detector b.
Since the groove-shaped member 11a has moved from the position of the first stopper 41, the detector a no longer detects and the second stopper 42 is released. Then, the groove member 11b moves to the position of the first stopper 41, is detected by the detector a, and the second stopper 42 is operated to stop the groove member 11c and the subsequent members.
The channel member 11 a is inverted by the reversing device 17 and placed on the hole machining work table 16. Then, the hole is processed by the hole processing means 20 and returned to the intermediate mounting table 15 by the reversing device 17 again. The time required for drilling varies depending on the specifications of the plasma torch and the articulated robot used, but is about 80 to 160 seconds in the present embodiment. At this time, the time required for positioning is about 10 seconds.
[0044]
The intermediate mounting table 15 is moved upward by the elevating cylinder 103 and, for example, a detection device (referred to as detector c) installed on the temporary receiving device 23 confirms that there is no preceding groove-shaped member. The member 11 a is passed over the second conveyor 21 and moved to the temporary receiving device 23. When the intermediate mounting table 15 is again moved downward by the elevating cylinder 103, the detector b does not detect the groove member 11a (sends no detection signal), and the first stopper 41 is released.
Then, the groove member 11b is carried to the intermediate mounting table 15, and the hole processing is performed in the same manner as the groove member 11a. The groove member 11c is stopped by the first stopper 41 until the hole machining of the groove member 11b is completed.
[0045]
The groove-shaped member 11a placed on the temporary receiving device 23 is placed on the press device 32 after positioning in the longitudinal direction. After the temporary receiving device 23 is retracted behind the press device 32 (left side in FIG. 1), end bending processing, that is, press processing on both sides of the channel member 11a is performed. The time required for pressing is about 10 seconds for positioning and about 50 seconds for end bending.
After the press working is completed, the groove-shaped member 11 a is placed on the third conveyor 36 by the carry-out device 34 and is carried to the product take-out port 35. Although the speed of the 3rd conveyor 36 is also arbitrary similarly to the 1st conveyor 14, in this Embodiment, it is about 10 m / min.
Then, the temporary receiving device 23 returns to the position where it overlaps with the pressing device 32, and the detector c on the temporary receiving device 23 stops detecting the groove member 11a and waits for the groove member 11b to be conveyed. Become.
After that, the groove members 11b, 11c,... Are continuously processed by this equipment and conveyed to the product outlet 35, but the preceding groove member 11 and the subsequent groove member 11 do not collide during the processing. Absent.
[0046]
The groove-shaped member 11 taken out from the product take-out port 35 by a lift car, a hoist or the like is shipped after post-treatment such as dross generated during drilling or product inspection. Through the processes as described above, it has become possible to continuously produce products with stable quality.
[0047]
In addition, this invention is not limited to the said embodiment, For example, you may provide multiple hole processing means. The time required for the hole processing in this embodiment is about 80 to 160 seconds, and the time required for the press processing is about 50 seconds. Therefore, there is much time during which the press apparatus is not working. For this reason, in order to shorten the drilling time, it is possible to increase the number of articulated robots as the drilling means as described above. Also, taking into consideration the problem that other operations cannot be performed during the operation time of the reversing device, it is possible to manufacture more efficiently by inserting the groove-shaped member in which the hole processing has been completed from both the left and right sides of the pressing device.
[0048]
【The invention's effect】
In the continuous manufacturing equipment for steel sleepers according to claims 1 to 9, since the first conveyor for storing a plurality of groove-shaped members is provided in the front portion, a large number of groove-shaped members are connected to the first conveyor at a time. It can be loaded on top and is time efficient.
Furthermore, since the groove members conveyed by the first conveyor can be taken out individually, the groove members on the respective devices can be prevented from colliding with each other and can be manufactured continuously and stably.
Moreover, since it has the 1st positioning device which aligns the groove-shaped member mounted on the hole processing worktable in a predetermined position, it can manufacture in a short time and can stabilize quality.
And since it has a temporary receiving device that can be advanced and retracted, it can be received from either the lateral direction (longitudinal direction of the groove-shaped member), and the installation position in the factory is limited Can also be installed. Moreover, manufacturing efficiency is improved by receiving and pressing the groove-shaped member after completion of the hole processing from both sides in the lateral direction.
Since the reversing device, the intermediate mounting table, the second conveyor, and the provisional receiving device are provided between the drilling work table and the press device, it is possible to continuously perform drilling and end bending.
[0049]
In particular, in the continuous manufacturing equipment for steel sleepers according to claim 2, since the articulated robot is three-dimensionally controlled by the articulated robot according to a predetermined program, it takes time to change the hole position. Therefore, it can be processed accurately.
In the continuous production equipment for steel sleepers according to claim 3, since the hole processing work table is provided with a support table that keeps the back surface of the groove bottom portion at a predetermined height with the groove bottom portion of the groove-shaped member facing up, Deviations in the height direction at the time of drilling can be suppressed within the tolerance range of the plate thickness.
In the continuous manufacturing equipment for steel sleepers according to claim 4, the first positioning device has an air cylinder for pulling each pressing member synchronously via a rope and centering the groove-shaped member. Therefore, the center position can be determined even if the length of the channel-shaped member is not constant, and even when a steel sleeper having a different length is manufactured, the setting change of the positioning device can be reduced.
In addition, since the counterweight is provided, when the centering is released by the air cylinder, it is possible to easily return to the original position without consuming energy.
[0050]
In the continuous manufacturing equipment for steel sleepers according to claim 5, since the first conveyor has first and second stoppers for individually stopping the movement of the groove-shaped member, the groove-shaped member is 1 Steel can be supplied continuously, and steel sleepers can be manufactured automatically.
In the continuous manufacturing equipment for steel sleepers according to claim 6, since the reversing device has at least two vertical rollers, the lateral movement of the groove-shaped member is prevented, and the position reference in the width direction is used at the time of drilling. Also, when the channel member moves in the vertical direction, scratches due to sliding can be prevented.
And since it has the pad which press-holds a groove-shaped member from the top, the shakiness at the time of inversion can be prevented and the quality of a product can be improved.
In the continuous manufacturing equipment for steel sleepers according to claim 7, since the lifting roller of the intermediate mounting table can protrude to a higher position than the fixed roller, the movement of the groove-shaped member in the width direction and the longitudinal direction can be performed. And enables rapid production.
In the continuous manufacturing equipment for steel sleepers according to claim 8, since the second positioning device has a pair of guide plates for performing centering in the width direction of the groove-shaped member in the lower mold, Since the guide plate does not move, the repair can be easily performed.
In the continuous manufacturing equipment for steel sleepers according to claim 9, since the carry-out device has a lift mechanism and a horizontal movement mechanism, it can prevent scratches caused by sliding with the mold and can move quickly. Yes.
[Brief description of the drawings]
FIG. 1 is a configuration diagram of a continuous manufacturing facility for steel sleepers according to an embodiment of the present invention.
FIGS. 2A and 2B are a side view and a front sectional view of the first conveyor, respectively.
FIG. 3 is a side sectional view showing the first conveyor and the intermediate mounting table.
FIG. 4 is a plan view showing the reversing device.
FIG. 5 is a front sectional view showing the reversing device.
FIG. 6 is a plan view showing the same width direction adjusting device.
FIG. 7 is a front view showing the same width direction adjusting device.
FIG. 8 is a right side view showing the first positioning device.
FIG. 9 is a plan view showing the intermediate mounting table.
FIGS. 10A and 10B are a right side view and a front view of the intermediate mounting table, respectively.
FIG. 11 is a front view of the press device.
FIGS. 12A and 12B are a left side view of the pressing device and a partial left side view showing the positional relationship between the pressing device and the groove-shaped member, respectively.
FIGS. 13A and 13B are a front view of the press device and a second positioning device, and a left side view of the press device and the second positioning device, respectively.
14A and 14B are a partial plan view and a front sectional view, respectively, of the third conveyor carry-out device.
FIGS. 15A to 15E are a plan view of a steel sleeper (AP type) according to a conventional example, a front view of the AP (AP type), a plan view of the same (Nabla type), and the same (Nabla type), respectively. ) And a side sectional view of the same (AP type, Nabla type).
[Explanation of symbols]
10 Continuous production facilities for steel sleepers 11 Channel members
11a Corner 12 Groove bottom
13 Front 14 First conveyor
15 Intermediate mounting table 16 Drilling work table
17 reversing device 18 first positioning device
20 hole processing means 21 second conveyor
22 Pressing position 23 Temporary receiving device
24 Lower mold 25 Lower mold
26 cradle 27 lower mold
28 Upper mold 29 Upper mold
30 Press base 31 Upper mold
32 Pressing device 34 Unloading device
35 Product outlet 36 Third conveyor
37 plates 38 plates
39 Roller 40 Side end
41 First stopper 42 Second stopper
43 Stopper piece 44 Stopper piece
45 Arm 46 Air cylinder
47 Piston rod 48 Front end
49 Wheel conveyor (fixed roller)
50 Extruding member (Pusher) 51 Rotating shaft
52 Right side 53 Return weight
54 Upper part 55 Air cylinder
56 Vertical roller 57 Reverse shaft
58 Holding member (metal) 59 Bearing
60 drive motor (rotation drive source) 61 pad
62 Cylinder 63 Opening
64 Auxiliary roller 65 Fixed shaft
66 Short shaft 66a Bearing
67 Bracket 68 Piston rod
68a Mounting bracket 69 cylinder
70 Bottom inner part 71 Upper part
72 Receiving roller (support) 73 Bearing
74 Receiving roller shaft 75 Width direction adjusting device
76 Support shaft 77 Bearing
78 Arm member 79 Arm member
80 bracket 81 axis
82 Pressure roller 83 Cylinder
84 Pressing member 84a stand
85 Pressing member 85a
86 rope 87 rope
88 Air cylinder 89 Counterweight
90 counterweight 91 piston rod
92 Bracket 92a stand
93 pulley 94 pulley
95 pulley 96 end face
97 End face 98 Release rope
99 Release rope 100 Lift roller
100a drive chain 100b drive chain
100c drive chain 100d drive chain
100e drive chain 100f drive chain
100g drive chain 100h drive chain
100i drive chain 101 lifting platform
101a base 102 moving motor
103 Lifting cylinder 104 Rod
105 Rotating bracket 106 Horizontal axis
107 Rotating arm 108 Support shaft
109 Supporting roller 110 Holding arm
111 Holding stand 112 Sprocket
113 Fixed base 114 Air cylinder
115 Moving table 116 Cylinder
117 Temporary cradle 118 Temporary roller
119 Second positioning device 120 Groove side pressing mechanism
120a rope 121 groove side pressing mechanism
121a rope 122 air cylinder
123 Counterweight 124 Counterweight
125 Taper roller 125a Upper end
126 Guide roller 127 Claw
128 Claw part 130 Claw part
131 Nail part 133 Nail
134 Claw 135 Lift mechanism
136 Horizontal movement mechanism 137 Air cylinder
138 Horizontal arm 139 Connecting member
140 Fixing member 141 Horizontal connecting arm
142 Chain conveyor 143 Driving means

Claims

A steel sleeper manufacturing facility for forming a rail mounting hole in a groove-shaped member cut to a predetermined length and performing end bending on both sides by a press device,
A first conveyor that conveys the groove-shaped member with the groove bottom facing down and stores a plurality of the groove-shaped members in a front portion;
An intermediate mounting table for individually taking out and temporarily mounting the channel members conveyed by the first conveyor;
The groove-shaped member placed on the intermediate mounting table is inverted and placed on the hole working table, or the groove-shaped member placed on the hole working table and finished drilling is again used as the intermediate mounting table. A reversing device for reversing and mounting,
A first positioning device for aligning the groove-shaped member placed on the hole working table at a predetermined position;
Hole processing means for performing hole processing of the rail mounting hole on the groove-shaped member positioned on the hole processing worktable;
A second conveyor that completes the hole processing and conveys the groove-shaped member placed on the intermediate mounting table in the longitudinal direction of the groove-shaped member to a position before the pressing position;
A temporary receiving device that is capable of advancing and retreating and placing the groove-shaped member conveyed to the pressing position by the second conveyor at the pressing position;
A press provided at the press working position, comprising a lower mold on both sides, a lower mold having a cradle in the center, and an upper mold on both sides corresponding to these, and an upper mold having a pressing table in the center. Equipment,
A second positioning device for aligning the groove-shaped member mounted on the pressing device at a predetermined position;
An unloading device for removing the groove-shaped member mounted on the pressing device from the pressing device after the press work is completed;
A third conveyor for carrying out the groove-shaped member taken out by the carry-out device to a product take-out port;
A continuous manufacturing facility for steel sleepers, characterized by comprising:

2. The steel according to claim 1, wherein the hole drilling means includes an articulated robot, a plasma torch that is three-dimensionally controlled by a program predetermined by the articulated robot, and a device attached to the plasma torch. Continuous manufacturing equipment for sleepers.

3. The steel-made steel according to claim 1, wherein the drilling work table includes a support table that keeps the bottom surface of the groove-shaped member at a predetermined height with the groove bottom portion of the groove-shaped member facing up. Sleeper continuous manufacturing equipment.

The first positioning device is configured so that the groove-shaped member is movable in the longitudinal direction freely and the both outer sides in the longitudinal direction of the groove-shaped member placed on the support base are opposed to each other. A pressure member provided, an air cylinder that pulls each of the pressure members synchronously via a rope, and centers the groove-shaped member; and when the centering is released by the air cylinder, the pressure member is The continuous manufacturing equipment for steel sleepers according to claim 3, further comprising a counterweight that urges the member outward in the longitudinal direction.

The first conveyor is attached to the front of the first conveyor in the moving direction according to the width of the channel member, and two adjacent channel members that move laterally on the first conveyor. The first and second stoppers for individually stopping the movement of the first stopper and the second stopper on the rear side are operated to release the first stopper on the front side. The continuous production equipment for steel sleepers according to any one of claims 1 to 4, wherein the steel sleepers are conveyed as they are by a first conveyor.

The reversing device has the groove shape conveyed in the hardware by a pusher following the first conveyor or the groove-shaped member, the lower part of which is disposed in a U-shaped metal object that is overlapped with the intermediate mounting table. At least two vertical rollers for stopping the lateral movement of the member, a pad that press-holds the groove-shaped member that is fitted into the hardware and is in contact with the vertical roller, and the groove-shaped member that is held by the pad The continuous manufacturing equipment for steel sleepers according to any one of claims 1 to 5, further comprising: a rotation drive source that rotates 180 degrees together with the hardware around a base end portion of the hardware.

The intermediate mounting table includes: a fixed roller that conveys the groove-shaped member in the width direction; and a lifting roller that can project to a higher position than the fixed roller and move the mounted groove-shaped member in the longitudinal direction. A continuous production facility for steel sleepers according to claim 6.

The steel according to any one of claims 1 to 7, wherein the second positioning device has a pair of guide plates in the lower mold for performing centering in the width direction of the groove-shaped member. Sleeper continuous manufacturing equipment.

In the unloading device, a claw at the front portion enters between the lower molds on both sides and the central cradle, lifts the groove-shaped member after the press working from below, and lifts it horizontally to take it out. It has a mechanism and a horizontal movement mechanism, The continuous manufacturing equipment of the steel sleepers of any one of Claims 1-8 characterized by the above-mentioned.